Crack Path Selection at the Interface of Wrought and Wire + Arc Additive Manufactured Ti-6Al-4 V

J. Zhang; Xhiang Zhang; Xueyuan Wang; J. Ding; Y. Traoré; S. Paddea; S. Williams

doi:10.1016/j.matdes.2016.05.027

Crack Path Selection at the Interface of Wrought and Wire + Arc Additive Manufactured Ti-6Al-4 V

J. Zhang, Xhiang Zhang, Xueyuan Wang, J. Ding, Y. Traoré, S. Paddea, S. Williams

Cranfield University

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Abstract

Crack propagation deviation tendency in specimens containing an interface between wrought alloy substrate and Wire + Arc Additive Manufacture (WAAM) built Ti-6Al-4 V is investigated from the viewpoints of microstructure, residual stress and bi-material system. It is found that a crack initiated at the interface tends to grow into the substrate that has equiaxed microstructure and lower resistance to fatigue crack propagation. Experimental observations are interpreted by finite element modelling of the effects of residual stress and mechanical property mismatch between the WAAM and wrought alloy. Residual stresses retained in the compact tension specimens are evaluated based on measured residual stress in the initial WAAM built wall. Cracks perpendicular to the interface kept a straight path owing to the symmetrical residual stress distribution. In this case the tangential stress in bi-material model is also symmetric and has the maximum value at the initial crack plane. In contrast, cracks parallel to the interface is inclined to grow towards the substrate due to the mode II (or sliding mode) stress intensity factor caused by the asymmetric residual stress field. Asymmetric tangential stress in the bi-material model also contributes to the observed crack deviation trend according to the maximum tangential stress criterion.

Original language	English
Pages (from-to)	365–375
Journal	Materials & Design
Volume	104
Early online date	12 May 2016
DOIs	https://doi.org/10.1016/j.matdes.2016.05.027
Publication status	Published - 15 Aug 2016

Bibliographical note

NOTICE: this is the author’s version of a work that was accepted for publication in Materials & Design. 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 & Design, 104, (15 Aug 2016) DOI: 10.1016/j.matdes.2016.05.027© 2016, Elsevier. Licensed under the Creative Commons Attribution-NonCommercial-NoDerivatives 4.0 International http://creativecommons.org/licenses/by-nc-nd/4.0/

Keywords

additive manufacturing
titanium alloy
crack path selection
microstructure
residual stress
bi-material
finite element model

Access to Document

10.1016/j.matdes.2016.05.027

Post-printAccepted author manuscript, 2.02 MBLicence: CC BY-NC-ND

Xiang Zhang
- Centre for Manufacturing and Materials - Professor in Structural Integrity
Person: Teaching and Research

Cite this

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title = "Crack Path Selection at the Interface of Wrought and Wire + Arc Additive Manufactured Ti-6Al-4 V",

abstract = "Crack propagation deviation tendency in specimens containing an interface between wrought alloy substrate and Wire + Arc Additive Manufacture (WAAM) built Ti-6Al-4 V is investigated from the viewpoints of microstructure, residual stress and bi-material system. It is found that a crack initiated at the interface tends to grow into the substrate that has equiaxed microstructure and lower resistance to fatigue crack propagation. Experimental observations are interpreted by finite element modelling of the effects of residual stress and mechanical property mismatch between the WAAM and wrought alloy. Residual stresses retained in the compact tension specimens are evaluated based on measured residual stress in the initial WAAM built wall. Cracks perpendicular to the interface kept a straight path owing to the symmetrical residual stress distribution. In this case the tangential stress in bi-material model is also symmetric and has the maximum value at the initial crack plane. In contrast, cracks parallel to the interface is inclined to grow towards the substrate due to the mode II (or sliding mode) stress intensity factor caused by the asymmetric residual stress field. Asymmetric tangential stress in the bi-material model also contributes to the observed crack deviation trend according to the maximum tangential stress criterion.",

keywords = "additive manufacturing, titanium alloy, crack path selection, microstructure, residual stress, bi-material, finite element model",

author = "J. Zhang and Xhiang Zhang and Xueyuan Wang and J. Ding and Y. Traor{\'e} and S. Paddea and S. Williams",

note = "NOTICE: this is the author{\textquoteright}s version of a work that was accepted for publication in Materials & Design. 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 & Design, 104, (15 Aug 2016) DOI: 10.1016/j.matdes.2016.05.027{\textcopyright} 2016, Elsevier. Licensed under the Creative Commons Attribution-NonCommercial-NoDerivatives 4.0 International http://creativecommons.org/licenses/by-nc-nd/4.0/",

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AU - Ding, J.

AU - Traoré, Y.

AU - Paddea, S.

AU - Williams, S.

N1 - NOTICE: this is the author’s version of a work that was accepted for publication in Materials & Design. 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 & Design, 104, (15 Aug 2016) DOI: 10.1016/j.matdes.2016.05.027© 2016, Elsevier. Licensed under the Creative Commons Attribution-NonCommercial-NoDerivatives 4.0 International http://creativecommons.org/licenses/by-nc-nd/4.0/

PY - 2016/8/15

Y1 - 2016/8/15

N2 - Crack propagation deviation tendency in specimens containing an interface between wrought alloy substrate and Wire + Arc Additive Manufacture (WAAM) built Ti-6Al-4 V is investigated from the viewpoints of microstructure, residual stress and bi-material system. It is found that a crack initiated at the interface tends to grow into the substrate that has equiaxed microstructure and lower resistance to fatigue crack propagation. Experimental observations are interpreted by finite element modelling of the effects of residual stress and mechanical property mismatch between the WAAM and wrought alloy. Residual stresses retained in the compact tension specimens are evaluated based on measured residual stress in the initial WAAM built wall. Cracks perpendicular to the interface kept a straight path owing to the symmetrical residual stress distribution. In this case the tangential stress in bi-material model is also symmetric and has the maximum value at the initial crack plane. In contrast, cracks parallel to the interface is inclined to grow towards the substrate due to the mode II (or sliding mode) stress intensity factor caused by the asymmetric residual stress field. Asymmetric tangential stress in the bi-material model also contributes to the observed crack deviation trend according to the maximum tangential stress criterion.

AB - Crack propagation deviation tendency in specimens containing an interface between wrought alloy substrate and Wire + Arc Additive Manufacture (WAAM) built Ti-6Al-4 V is investigated from the viewpoints of microstructure, residual stress and bi-material system. It is found that a crack initiated at the interface tends to grow into the substrate that has equiaxed microstructure and lower resistance to fatigue crack propagation. Experimental observations are interpreted by finite element modelling of the effects of residual stress and mechanical property mismatch between the WAAM and wrought alloy. Residual stresses retained in the compact tension specimens are evaluated based on measured residual stress in the initial WAAM built wall. Cracks perpendicular to the interface kept a straight path owing to the symmetrical residual stress distribution. In this case the tangential stress in bi-material model is also symmetric and has the maximum value at the initial crack plane. In contrast, cracks parallel to the interface is inclined to grow towards the substrate due to the mode II (or sliding mode) stress intensity factor caused by the asymmetric residual stress field. Asymmetric tangential stress in the bi-material model also contributes to the observed crack deviation trend according to the maximum tangential stress criterion.

KW - additive manufacturing

KW - titanium alloy

KW - crack path selection

KW - microstructure

KW - residual stress

KW - bi-material

KW - finite element model

U2 - 10.1016/j.matdes.2016.05.027

DO - 10.1016/j.matdes.2016.05.027

M3 - Article

SN - 0261-3069

VL - 104

SP - 365

EP - 375

JO - Materials & Design

JF - Materials & Design

ER -

Crack Path Selection at the Interface of Wrought and Wire + Arc Additive Manufactured Ti-6Al-4 V

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