Damage tolerant design of additively manufactured metallic components subjected to cyclic loading: State of the art and challenges

Uwe Zerbst, Giovanni Bruno , Jean-Yves Buffiere, Thomas Wegener, Thomas Niendorf, Tao Wu, Xiang Zhang, Nikolai Kashaev, Giovanni Meneghetti, Nik Hrabe, Mauro Madia, Tiago Werner, Kai Hilgenberg, Martina Koukolíková, Radek Procházka, Jan Džugan, Benjamin Möller, Stefano Beretta, Alexander Evans, Rainer WagenerKai Schnabel

    Research output: Contribution to journalReview articlepeer-review

    106 Citations (Scopus)
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    Undoubtedly, a better understanding and the further development of approaches for damage tolerant component design of AM parts are among the most significant challenges currently facing the use of these new technologies. This article presents a thorough overview of the discussion at an international workshop on the topic. It aims to provide a review of the parameters affecting the damage tolerance of parts produced by additive manufacturing (shortly, AM parts) with special emphasis on the process parameters intrinsic to the AM technologies, the resulting defects and the residual stresses. Based on these aspects, basic concepts are reviewed and critically discussed specifically for AM materials: - Criteria for damage tolerant component design; - Criteria for the determination of fatigue and fracture properties; - Strategies for the determination of the fatigue life in dependence of different manufacturing conditions; - Methods for the quantitative characterization of microstructure and defects; - Methods for the determination of residual stresses; - Effect of the defects and the residual stresses on the fatigue life and behaviour.We see that many of the classic concepts need to be expanded in order to fit with the particular microstructure (grain size and shape, crystal texture) and defect distribution (spatial arrangement, size, shape, amount) present in AM (in particular laser powder bed fusion). For instance, 3D characterization of defects becomes essential, since the defect shapes in AM are diverse and impact the fatigue life in a different way than in the case of conventionally produced components. Such new concepts have immediate consequence on the way one should tackle the determination of the fatigue life of AM parts; for instance, since a classification of defects and a quantification of the tolerable shapes and sizes is still missing, a new strategy must be defined, whereby theoretical calculations (e.g. finite element modeling) allow determining the maximum tolerable defect size, and non-destructive testing (NDT) techniques are required to detect whether such defects are indeed present in the component. Such examples show how component design, damage and failure criteria, and characterization (and/or NDT) become for AM parts fully interlinked. We conclude that the homogenization of these fields represents the current challenge for the engineer and the materials scientist.

    Original languageEnglish
    Article number100786
    JournalProgress in Materials Science
    Early online date1 Mar 2021
    Publication statusPublished - Aug 2021

    Bibliographical note

    2021, Elsevier. Licensed under the Creative Commons AttributionNonCommercial-NoDerivatives 4.0 International

    Copyright © and Moral Rights are retained by the author(s) and/ or other copyright owners. A copy can be downloaded for personal non-commercial research or study, without prior permission or charge. This item cannot be reproduced or quoted extensively from without first obtaining permission in writing from the copyright holder(s). The content must not be changed in any way or sold commercially in any format or medium without the formal permission of the copyright holders.


    • Additive manufacturing
    • Fatigue loading
    • component assessment
    • damage tolerance
    • defects
    • residual stresses
    • Damage tolerance
    • Component assessment
    • Residual stresses
    • Defects

    ASJC Scopus subject areas

    • Engineering(all)
    • Materials Science(all)


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