Fatigue life prediction for PBF-LB Ti6A14V with as-built surface under nonproportional loads using an incremental fatigue damage model

This study evaluates the Ottosen–Stenström–Ristinmaa (OSR) incremental fatigue damage model for predicting fatigue life in powder bed fusion with laser beam (PBF-LB) Ti6Al4V notched specimens. To fit the OSR model, we conduct constant-amplitude tension-compression fatigue tests on PBF-LB Ti6Al4V specimens with as-built surface. Our results highlight a relatively low scatter in fatigue life data for PBF-LB Ti6Al4V across different studies, a critical factor for reliable design against fatigue failure. The study suggests that the stress gradient effect is influenced by the as-built surface, which carries load differently from the target build geometry due to surface undulations. The OSR model effectively captures the characteristics of Wöhler curves for various notch geometries and stress ratios. We validate the OSR model with out-of-phase tension-torsion tests, demonstrating that it provides safe fatigue life predictions for nonproportional loads. Overall, our findings show that the OSR model offers conservative fatigue life predictions for PBF-LB Ti6Al4V, underscoring its practical utility and reinforcing the suitability of PBF-LB Ti6Al4V for aircraft applications.