<p>Ti-6Al-4V (Ti64), widely used in aerospace components for its high specific strength and corrosion resistance, is increasingly produced by additive manufacturing (AM) to enhance material efficiency and design flexibility. However, its fatigue performance remains highly variable due to process-induced microstructural heterogeneities and inherent defects. Since aerospace components are designed following damage-tolerant principles, understanding fatigue crack growth (FCG) behavior in AM Ti64 is essential for reliable life prediction. This review critically examines FCG in Ti64, focusing on the influence of build orientation, processing routes, heat treatment, mean stress, defects, and environmental conditions. These factors, through their effect on the microstructure, govern crack propagation. Achieving consistent and predictable FCG behavior requires standardized test reporting, high-resolution microstructural and defect characterization, and data-driven approaches that link processing, microstructure, and fatigue response. To complement this mechanistic perspective, a meta-analysis of 67 studies assessed how FCG research in AM Ti64 is reported. Only 66 percent of studies included details on manufacturing processes and specimen preparation, and just 68 percent documented feedstock characteristics and material properties, whereas 99 percent reported testing conditions. These gaps highlight the need for more consistent and harmonized reporting. To address this, this review introduces a novel completeness index (<i>θ</i><sub>C</sub>), a reporting benchmark grounded in AM and FCG standards, to assess documentation quality across 67 studies. The analysis reveals average reporting completeness of 74.9%, with critical gaps in reporting preheat temperature details and feedstock specifications. Such standardization will enhance reproducibility, enable meaningful data comparisons, and advance data-driven FCG research in AM.</p>

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Fatigue Crack Growth Phenomena in Additively Manufactured Ti-6Al-4V

  • Samuel Onimpa Alfred

摘要

Ti-6Al-4V (Ti64), widely used in aerospace components for its high specific strength and corrosion resistance, is increasingly produced by additive manufacturing (AM) to enhance material efficiency and design flexibility. However, its fatigue performance remains highly variable due to process-induced microstructural heterogeneities and inherent defects. Since aerospace components are designed following damage-tolerant principles, understanding fatigue crack growth (FCG) behavior in AM Ti64 is essential for reliable life prediction. This review critically examines FCG in Ti64, focusing on the influence of build orientation, processing routes, heat treatment, mean stress, defects, and environmental conditions. These factors, through their effect on the microstructure, govern crack propagation. Achieving consistent and predictable FCG behavior requires standardized test reporting, high-resolution microstructural and defect characterization, and data-driven approaches that link processing, microstructure, and fatigue response. To complement this mechanistic perspective, a meta-analysis of 67 studies assessed how FCG research in AM Ti64 is reported. Only 66 percent of studies included details on manufacturing processes and specimen preparation, and just 68 percent documented feedstock characteristics and material properties, whereas 99 percent reported testing conditions. These gaps highlight the need for more consistent and harmonized reporting. To address this, this review introduces a novel completeness index (θC), a reporting benchmark grounded in AM and FCG standards, to assess documentation quality across 67 studies. The analysis reveals average reporting completeness of 74.9%, with critical gaps in reporting preheat temperature details and feedstock specifications. Such standardization will enhance reproducibility, enable meaningful data comparisons, and advance data-driven FCG research in AM.