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<p>Laser-directed energy deposition (L-DED) demonstrates high reliability in repairing titanium alloy components, validated through fatigue assessments of Ti60 heterogeneous structures containing base material (BM) and deposited zone (DZ). The present L-DED process achieves robust metallurgical bonding with near-isotropic DZ microstructures, yielding minimal strength mismatch and comparable fatigue lives between BM and DZ. Deposited material can be near defect-free as confirmed via X-ray computed tomography. A cyclic plasticity model, calibrated using wrought material data, simulates interfacial multi-axial stresses and strain localization. Critical plane-based models predict fatigue lives effectively, demonstrating the applicability of conventional assessment frameworks in medium- to high-cycle fatigue regime. DZ shows better defect tolerance than the BM, with its higher fatigue limit based on Murakami’s empirical model. Stress triaxiality near the interface accelerates low-cycle fatigue damage, yet no interfacial failures occur, highlighting the process’s mechanical robustness. These findings validate the L-DED process in balancing defect control and performance, providing a reliable methodology for aerospace component repair.</p>

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Fatigue damage and life assessment of Ti60 alloy fabricated by laser-directed energy deposition

  • 期刊论文

  • 发表日期：

    2025年7月15日

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  • Shengzhe Jin,
  • Jinhan Chen,
  • Tinglian Zhang,
  • Qi Liu,
  • Fan Wu,
  • Wei Chen

摘要

Laser-directed energy deposition (L-DED) demonstrates high reliability in repairing titanium alloy components, validated through fatigue assessments of Ti60 heterogeneous structures containing base material (BM) and deposited zone (DZ). The present L-DED process achieves robust metallurgical bonding with near-isotropic DZ microstructures, yielding minimal strength mismatch and comparable fatigue lives between BM and DZ. Deposited material can be near defect-free as confirmed via X-ray computed tomography. A cyclic plasticity model, calibrated using wrought material data, simulates interfacial multi-axial stresses and strain localization. Critical plane-based models predict fatigue lives effectively, demonstrating the applicability of conventional assessment frameworks in medium- to high-cycle fatigue regime. DZ shows better defect tolerance than the BM, with its higher fatigue limit based on Murakami’s empirical model. Stress triaxiality near the interface accelerates low-cycle fatigue damage, yet no interfacial failures occur, highlighting the process’s mechanical robustness. These findings validate the L-DED process in balancing defect control and performance, providing a reliable methodology for aerospace component repair.