Design-Informed Evaluation and Fretting Damage Mapping of Additive-Manufactured Ti-6Al-4V Components

This paper experimentally investigates the fretting fatigue behavior of metal additive-manufactured Ti-6Al-4V alloy specimens fabricated using the selective laser melting (SLM) method, focusing on damage characterization and fatigue life assessment. Based on the ASTM E466 standard, the test components were manufactured using metal 3D printing technology. Fretting fatigue tests were conducted under varying axial stress levels and contact loads, followed by microscopic examinations using scanning electron microscopy (SEM) to analyze damage mechanisms. A fretting map was developed based on SEM observations, providing insights into damage evolution under different loading conditions. These findings contribute to a better understanding of the relationship between fretting fatigue parameters and failure mechanisms. The developed fretting map and experimental observations provide a foundation for further studies aimed at enhancing the fretting fatigue life assessment of standard specimens for different test parameters. Finally, this paper includes design-oriented evaluation frameworks that can guide engineers in integrating AM components into safety-critical systems under fretting fatigue conditions.