Fatigue Prediction for Additive Manufactured (AM) Metallic Components

In this Phase I work, we will expose the effects of an additively-manufactured (AM) part’s inherent defects (including both volumetric and surface defects) and residual stress on its subsequent fatigue strength based on carefully-executed manufacturing, microstructure characterization, numerical simulations, and mechanical experiments. Results from this study will leverage consolidated design and qualification efforts for providing a means to assess the severity of AM product defects and residual stress prior to and during product service. A unique ‘fracture mechanics approach’ will be taken by exploiting the classical Murakami’s fatigue model for more accurate fatigue life estimation. This fatigue model will be calibrated and tested using in-hand and to-be-obtained fatigue data. The objectives of the Phase I project will demonstrate the feasibility by performing limited predictions of the fatigue performance of 17-4 PH SS, through experimental, analytical, and computational activities to evaluate, calibrate, validate.