Size Effect of High‐Cycle Fatigue Performance in Additively Manufactured Ti‐6Al‐4V Alloy
ABSTRACT As AM engineering components often possess complex structures and varying cross‐sectional dimensions, they frequently exhibit unstable service performance due to the print dimension size effect. This variability in performance is one of the most typical problems in AM components. This study investigates the size effect on the high‐cycle fatigue performance of the widely used AM alloy, Ti‐6Al‐4V. The influence of sample size on fatigue performance is explored through fatigue source analysis, fatigue life analysis, and defect statistics. A new statistical model is proposed to predict the theoretical largest defect in samples with small dimensions, based on observations of relatively large regions. This model is particularly suitable for the commonly thin‐walled AM components. The corresponding fatigue life prediction is then achieved by integrating the microstructure void coupling (MVC) model.
Authors
- Zhan Qu (ORCID: https://orcid.org/0000-0002-3401-7439)
- Xin Bai (ORCID: https://orcid.org/0000-0002-8157-1264)
- Zhenkai Zhao (ORCID: https://orcid.org/0009-0004-9013-9600)
- Zhenjun Zhang (ORCID: https://orcid.org/0000-0002-7695-1836)
- Zhefeng Zhang (ORCID: https://orcid.org/0000-0002-8165-9549)
- Rui Liu (ORCID: https://orcid.org/0000-0001-6353-6193)
- Yining Zhang (ORCID: https://orcid.org/0000-0002-7101-1554)
- Lijia Chen (ORCID: https://orcid.org/0000-0001-9172-1599)
- Hanzhong Liu (ORCID: https://orcid.org/0000-0003-0752-845X)
Institutions
- University of Science and Technology of China (CN)
- Shenyang University of Technology (CN)
- Chinese Academy of Sciences (CN)
Publication Details
- Journal
- Fatigue & Fracture of Engineering Materials & Structures
- Published
- 2025-08-14
- DOI
- https://doi.org/10.1111/ffe.70060
- Primary Topic
- Additive Manufacturing Materials and Processes
- Type
- article
- Field-Weighted Citation Impact
- 0.00
Funders
- Innovative Research Group Project of the National Natural Science Foundation of China
- Youth Innovation Promotion Association of the Chinese Academy of Sciences