PSI - Issue 75

J. Havia et al. / Procedia Structural Integrity 75 (2025) 43–52 Havia et al. / Structural Integrity Procedia (2025)

45 3

Filler wire AlMg5 d = 1.2 mm was used in the DED process. The deposition and welding parameters are given in Table 3. In case 2, where DED component was welded on the plate, opening angle 50° with 2mm root face was used. Fatigue testing was conducted with a servo-hydraulic 400 kN test setup. Fatigue tests were conducted under load controlled uniaxial fatigue load with sinusoidal waveform and stress ratio of R = 0.1. Strain gauges were positioned at the 0.4 t distance from the tip of the oval-shaped reinforcement (weld toe) to obtain the amount of secondary bending stresses due to the angular distortion and stiffness of a test setup. The failure criterion for the fatigue tests was the total rupture of the specimen.

Fig. 2. (a) specimen dimensions, (b-f) Manufacturing of specimens and (g) fatigue testing. The deposition and welding parameters are given in Table 3. The first and second pass of deposition was performed next to each other using higher wire feed rate to secure penetration to plate attachment. The deposition and welding operations were performed using Kemppi X5 power supply with Yaskawa robot station. The polished sections of critical location are illustrated in Fig. 3. The weld toe angle and radius are smoothest in DED on plate specimens (Case 1) whereas, DED on cladded surface (Case 3) had the sharp transition from base plate to DED wall.

Table 2. Mechanical properties of materials

Material (delivery condition)

f y [MPa]

f u [MPa]

A 50 [%]

5083 (H111)

160

315 MPa 25

Fig. 3. Polished sections of the specimens at fatigue critical location.