PSI - Issue 75

Available online at www.sciencedirect.com Available online at www.sciencedirect.com ScienceDirect Structural Integrity Procedia (2025) 000 – 000 ScienceDirect Structural Integrity Procedia (2025) 000 – 000

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ScienceDirect

Procedia Structural Integrity 75 (2025) 43–52

© 2025 The Authors. Published by ELSEVIER B.V. This is an open access article under the CC BY-NC-ND license (https://creativecommons.org/licenses/by-nc-nd/4.0) Peer-review under the responsibility of Dr Fabien Lefebvre with at least 2 reviewers per paper © 2025 The Authors. Published by ELSEVIER B.V. This is an open access article under the CC BY-NC-ND license (https://creativecommons.org/licenses/by-nc-nd/4.0) Peer-review under responsibility of the scientific committee of the Fatigue Design 2025 organizers Abstract Directed energy deposition with electric arc (DED-arc) can be used to manufacture structurally optimized components with high deposition rate. Furthermore, total manufacturing productivity can be increased by combining DED components with conventional plate and profile structures. The objective of the current work is to study different joining techniques in DED-to-plate and DED to-DED configurations from the fatigue behavior viewpoint in 5000 series aluminum joints. Fatigue testing was carried out to study the performance. Residual stress and local geometry measurements were used as an input value for numerical analysis with effective notch stress (ENS) and multiparametric 4R method. The results indicated that added DED features were in line with nominal and ENS design recommendations. Depositing the detail directly on the plate resulted in the best fatigue strength due to decreased residual stresses and smooth local geometry. © 2025 The Authors. Published by ELSEVIER B.V. This is an open access article under the CC BY-NC-ND license (https://creativecommons.org/licenses/by-nc-nd/4.0) Peer-review under responsibility of the scientific committee of the Fatigue Design 2025 organizers Abstract Directed energy deposition with electric arc (DED-arc) can be used to manufacture structurally optimized components with high deposition rate. Furthermore, total manufacturing productivity can be increased by combining DED components with conventional plate and profile structures. The objective of the current work is to study different joining techniques in DED-to-plate and DED to-DED configurations from the fatigue behavior viewpoint in 5000 series aluminum joints. Fatigue testing was carried out to study the performance. Residual stress and local geometry measurements were used as an input value for numerical analysis with effective notch stress (ENS) and multiparametric 4R method. The results indicated that added DED features were in line with nominal and ENS design recommendations. Depositing the detail directly on the plate resulted in the best fatigue strength due to decreased residual stresses and smooth local geometry. Keywords: Aluminum; Welding; Fatigue, Arc-DED; Local approaches Fatigue Design 2025 (FatDes 2025) Fatigue behavior of 5000 series aluminum DED component joined to plate in the non-load carrying configuration Fatigue Design 2025 (FatDes 2025) Fatigue behavior of 5000 series aluminum DED component joined to plate in the non-load carrying configuration J. Havia a *, K. Lipiäinen a , Antti Ahola a , T. Skriko ab a Steel Strucutres, LUT University, Yliopistonkatu 34, 53850 Lappeenranta, Finland b Welding Technology, LUT University, Yliopistonkatu 34, 53850 Lappeenranta, Finland J. Havia a *, K. Lipiäinen a , Antti Ahola a , T. Skriko ab a Steel Strucutres, LUT University, Yliopistonkatu 34, 53850 Lappeenranta, Finland b Welding Technology, LUT University, Yliopistonkatu 34, 53850 Lappeenranta, Finland

Keywords: Aluminum; Welding; Fatigue, Arc-DED; Local approaches

* Corresponding author. Tel.: +358 50 341 6070 E-mail address: juho.havia@lut.fi

2452-3216 © 2025 The Authors. Published by ELSEVIER B.V. This is an open access article under the CC BY-NC-ND license (https://creativecommons.org/licenses/by-nc-nd/4.0) Peer-review under responsibility of the scientific committee of the Fatigue Design 2025 organizers 2452-3216 © 2025 The Authors. Published by ELSEVIER B.V. This is an open access article under the CC BY-NC-ND license (https://creativecommons.org/licenses/by-nc-nd/4.0) Peer-review under responsibility of the scientific committee of the Fatigue Design 2025 organizers * Corresponding author. Tel.: +358 50 341 6070 E-mail address: juho.havia@lut.fi

2452-3216 © 2025 The Authors. Published by ELSEVIER B.V. This is an open access article under the CC BY-NC-ND license (https://creativecommons.org/licenses/by-nc-nd/4.0) Peer-review under the responsibility of Dr Fabien Lefebvre with at least 2 reviewers per paper 10.1016/j.prostr.2025.11.006