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      Defects in Electron Beam Melted Ti-6Al-4V: Fatigue Life Prediction Using Experimental Data and Extreme Value Statistics

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          Abstract

          Electron beam melting is a powder bed fusion (PBF) additive manufacturing (AM) method for metals offering opportunities for the reduction of material waste and freedom of design, but unfortunately also suffering from material defects from production. The stochastic nature of defect formation leads to a scatter in the fatigue performance of the material, preventing wider use of this production method for fatigue critical components. In this work, fatigue test data from electron beam melted Ti-6Al-4V specimens machined from as-built material are compared to deterministic fatigue crack growth calculations and probabilistically modeled fatigue life. X-ray computed tomography (XCT) data evaluated using extreme value statistics are used as the model input. Results show that the probabilistic model is able to provide a good conservative life estimate, as well as accurate predictive scatter bands. It is also shown that the use of XCT-data as the model input is feasible, requiring little investigated material volume for model calibration.

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          Most cited references 43

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          Overview of Materials Qualification Needs for Metal Additive Manufacturing

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            Effects of processing on microstructure and mechanical properties of a titanium alloy (Ti–6Al–4V) fabricated using electron beam melting (EBM), part 1: Distance from build plate and part size

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              Critical assessment of the fatigue performance of additively manufactured Ti–6Al–4V and perspective for future research

               P. Li,  A Fatemi,  N. Phan (2016)
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                Author and article information

                Contributors
                Role: Academic Editor
                Journal
                Materials (Basel)
                Materials (Basel)
                materials
                Materials
                MDPI
                1996-1944
                30 January 2021
                February 2021
                : 14
                : 3
                Affiliations
                [1 ]Division of Materials Science, Luleå University of Technology, 731 87 Luleå, Sweden; pia.akerfeldt@ 123456ltu.se (P.Å.); marta-lena.antti@ 123456ltu.se (M.-L.A.)
                [2 ]Division 9654: Materials Engineering, GKN Aerospace, 461 38 Trollhättan, Sweden; thomas.no.hansson@ 123456gknaerospace.com
                [3 ]Division 9641: Solid Mechanics, GKN Aerospace, 461 38 Trollhättan, Sweden; sushovan.roychowdhury@ 123456gknaerospace.com (S.R.); tomas.mansson@ 123456gknaerospace.com (T.M.)
                [4 ]Division 9633: Materials and Inspection Technologies, GKN Aerospace, 461 38 Trollhättan, Sweden; mats.delin@ 123456gknaerospace.com
                Author notes
                [* ]Correspondence: viktor.sandell@ 123456ltu.se
                Article
                materials-14-00640
                10.3390/ma14030640
                7866540
                © 2021 by the authors.

                Licensee MDPI, Basel, Switzerland. This article is an open access article distributed under the terms and conditions of the Creative Commons Attribution (CC BY) license ( http://creativecommons.org/licenses/by/4.0/).

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