An experimental study of residual stress and direction-dependence of fatigue crack growth behaviour in as-built and stress-relieved selective-laser-melted Ti6Al4V

Abdul Syed, Bilal Ahmad, Hua Guo, Thays Machry, David Eatock, Jonathan Meyer, Michael Fitzpatrick, Xiang Zhang

Research output: Contribution to journalArticle

3 Citations (Scopus)


Selective-laser-melting (SLM) is a powder-bed fusion additive-manufacturing process that has the potential to deliver three-dimensional complex parts with mechanical properties comparable or superior to parts produced via traditional manufacturing using cast and wrought alloys. Concerns for metallic parts built via SLM are the process-induced residual stresses, and anisotropic mechanical properties. This paper investigates the effect of residual stresses on the fatigue crack growth rate of SLM Ti6Al4V in as-built and stress-relieved conditions. Neutron diffraction and the contour method are employed to measure residual stresses in compact-tension samples. Neutron diffraction results are in good agreement with the contour method. It was found that tensile stresses are present at the notch root and the free edge areas, and compressive stress is seen in the middle of the sample. The tensile stresses in the as-built condition resulted in a higher fatigue crack growth rate. After stress relieving by heat treatment, the tensile residual stress diminished by around 90%, resulting in decreased crack growth rate. The build direction was seen to affect the crack growth rate, although the trend was different between the as-built and stress-relieved conditions.
Original languageEnglish
Pages (from-to)246-257
Number of pages12
JournalMaterials Science and Engineering: A
Early online date6 Apr 2019
Publication statusPublished - 7 May 2019


Bibliographical note

NOTICE: this is the author’s version of a work that was accepted for publication in Materials Science and Engineering: A. Changes resulting from the publishing process, such as peer review, editing, corrections, structural formatting, and other quality control mechanisms may not be reflected in this document. Changes may have been made to this work since it was submitted for publication. A definitive version was subsequently published in Materials Science and Engineering: A, [775], (2019) DOI: 10.1016/j.msea.2019.04.023

© 2019, Elsevier. Licensed under the Creative Commons Attribution-NonCommercial-NoDerivatives 4.0 International


  • Additive manufacturing
  • Contour method
  • Fatigue crack propagation
  • Residual stress
  • Selective laser melting
  • Titanium alloys

ASJC Scopus subject areas

  • Materials Science(all)
  • Condensed Matter Physics
  • Mechanics of Materials
  • Mechanical Engineering

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