PSI - Issue 75

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

www.elsevier.com/locate/procedia

ScienceDirect

Procedia Structural Integrity 75 (2025) 19–28

© 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 Abstract The structural reliability and consistent quality of additively manufactured (AM) materials are of outmost importance in cyclically loaded critical components. In this study, a structural re-design and material selection based on an existing aluminum component was conducted. The component was manufactured using a titanium alloy with the laser powder bed fusion (L-PBF) technique. Experimental fatigue tests were carried for the components manufactured using two different L-PBF setups. The effect of shot peening was studied as a potential fatigue performance improvement method. In addition, surface quality and metallurgical analysis were conducted, and post-mortem fractography was carried out using scanning electron microscopy (SEM). The AM component clearly exceeded design requirements for maximum service load considering the existing structure. The results highlight the potential of AM techniques for component manufacturing in both new designs and replacing conventionally manufactured parts. © 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 Keywords: Additive manufacturing; Directed energy deposition; Fatigue strenght Fatigue Design 2025 (FatDes 2025) Fatigue performance of a titanium component produced by laser powder bed fusion Kalle Lipiäinen a *, Mika Vaskelainen b , Matias Mattila b , Heini Järvinen b , Tero Pesonen a , Shahriar Afkhami c , Antti Ahola a a Steel Structures, Lappeenranta-Lahti University of Technology LUT, P.O. Box 20, FI-53851 Lappeenranta, Finland b Patria Aviation Oy, Lentokonetehtaantie 3, FI-35600 Halli, Finland c Welding technology, Lappeenranta-Lahti University of Technology LUT, P.O. Box 20, FI-53851 Lappeenranta, Finland

* Corresponding author. Tel.: +358 50 5712844 E-mail address: kalle.lipiainen@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 the responsibility of Dr Fabien Lefebvre with at least 2 reviewers per paper 10.1016/j.prostr.2025.11.003