PSI - Issue 19

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Available online at www.sciencedirect.com Structural Integrity Procedia 00 (2019) 000 – 000 Structural Integrity Procedia 00 (2019) 000 – 000

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ScienceDirect

Procedia Structural Integrity 19 (2019) 380–387

Fatigue Design 2019 Influence on the fatigue behavior of additively manufactured aluminum structures Rainer Wagener, Matilde Scurria, Heinz Kaufmann, Tobias Melz Fraunhofer Insitute for Structural Durability and System Reliability LBF, Bartningstraße 47, 64289 Darmstadt, Germany Fatigue Design 2019 Influence on the fatigue behavior of additively manufactured aluminum structures Rainer Wagener, Matilde Scurria, Heinz Kaufmann, Tobias Melz Fraunhofer Insitute for Structural Durability and System Reliability LBF, Bartningstraße 47, 64289 Darmstadt, Germany The development of additively manufactured structures and products should preferably be performed in a virtual environment from the first sketch to the printed component. In order to get a high quality product that can be used as safety relevant component under cyclic loading, the fatigue assessment including the structure optimization with respect to the exploitation of the lightweight design potential requires suitable numerical approaches. Therefore, the local component-related material behavior has to be determined and considered. During the AM process multiple influences on the cyclic material behavior, caused for instance by the exposure lighting strategy or surface conditions, lead to mutual interactions between the load and built orientation on the fatigue properties. Caused by industrial needs for short development cycles and reduced numerical effort, the requirements on a digital twin for the fatigue assessment are growing and only satisfying with an adjusted numerical concept with optimized material parameters. In this work, the influences of the manufacturing process on the cyclic stress-strain behavior as well as on the fatigue life will be discussed. Therefore, load- and strain-controlled fatigue test were performed and the results are summarized in order to establish a better understanding on the fatigue behavior of additively manufactured components and parts. The development of additively anufactured structures and products should preferably be performed in a virtual environment from the first sketch to the printed component. In order to get a high quality product that can be used as safety relevant component under cyclic loading, the fatigue assessment including the structure optimization with respect to the exploitation of the lightweight design potential requires suitable numerical approaches. Therefore, the local component-related material behavior has to be determined and considered. During the AM process multiple influences on the cyclic material behavior, caused for instance by the exposure lighting strategy or surface conditions, lead to mutual interactions between the load and built orientation on the fatigue properties. Caused by industrial needs for short development cycles and reduced numerical effort, the requirements on a digital twin for the fatigue assessment are growing and only satisfying with an adjusted numerical concept with optimized material parameters. In this work, the influences of the manufacturing process on the cyclic stress-strain behavior as well as on the fatigue life will be discussed. Therefore, load- and strain-controlled fatigue test were performed and the results are summarized in order to establish a better understanding on the fatigue behavior of additively manufactured components and parts. Abstract Abstract

© 2019 The Authors. Published by Elsevier B.V. Peer-review under responsibility of the Fatigue Design 2019 Organizers. © 2019 The Authors. Published by Elsevier B.V. Peer-review under responsibility of the Fatigue Design 2019 Organizers. © 2019 The Authors. Published by Elsevier B.V. Peer-review under responsibility of the Fatigue Design 2019 Organizers. Keywords: Cyclic material behavior, digital twin, fatigue life curve, Incremental Step Test Keywords: Cyclic material behavior, digital twin, fatigue life curve, Incremental Step Test

1. Additive manufacturing 1. Additive manufacturing

The new production technology of additive manufacturing is directly linked to a purely virtual design and engineering process. From the first sketch to the printing process, the whole production chain can be simulated numerically. Therefore a new quality of information has to be available, which improve the fatigue approach with respect to manufacturing influences on material properties. In order to enable the implementation of such data, methods are required to manage the local manufacturing and the service related data as well as their interactions. The new production technology of additive manufacturing is directly linked to a purely virtual design and engineering process. From the first sketch to the printing process, the whole production chain can be simulated numerically. Therefore a new quality of information has to be available, which improve the fatigue approach with respect to manufacturing influences on material properties. In order to enable the implementation of such data, methods are required to manage the local manufacturing and the service related data as well as their interactions.

2452-3216 © 2019 The Authors. Published by Elsevier B.V. Peer-review under responsibility of the Fatigue Design 2019 Organizers. 2452-3216 © 2019 The Authors. Published by Elsevier B.V. Peer-review under responsibility of the Fatigue Design 2019 Organizers.

2452-3216 © 2019 The Authors. Published by Elsevier B.V. Peer-review under responsibility of the Fatigue Design 2019 Organizers. 10.1016/j.prostr.2019.12.041