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Additively manufactured (AM) parts are increasingly used with as-built surfaces in the aerospace industry. One of the challenges resulting from the use of as-built AM surfaces is degraded fatigueFatigue life caused by surface roughnessSurface roughness. Assessing fatigueFatigue life due to surface roughnessSurface roughness with traditional fracture-based approaches can be challenging due to the complexities of small crackCrack growth effects exhibited by shallow surface roughnessSurface roughness defects. This paper explores both traditional fracture mechanicsFracture mechanics tools and modificationsModification to crackCrack growth algorithms by correcting for small crackCrack effects using an in-house developed crackCrack growth code. Three modificationsModification are explored and compared: (1) addition of a small material dependent increment to the crackCrack length, (2) addition of the cyclic plastic zone size to the crackCrack length, and (3) elimination of crackCrack closure effects for small cracksCrack. FatigueFatigue lives of test coupons are calculated based on the maximum pit depth of the as-built surface and compared against fatigueFatigue test results from literature.

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Fracture-Based Fatigue Life Prediction of Additively Manufactured Parts with As-Built Surface Roughness

  • 会议论文

  • 发表日期：

    2025年

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  • Leland Shimizu,
  • Xueyong Qu,
  • Jacob Rome

摘要

Additively manufactured (AM) parts are increasingly used with as-built surfaces in the aerospace industry. One of the challenges resulting from the use of as-built AM surfaces is degraded fatigueFatigue life caused by surface roughnessSurface roughness. Assessing fatigueFatigue life due to surface roughnessSurface roughness with traditional fracture-based approaches can be challenging due to the complexities of small crackCrack growth effects exhibited by shallow surface roughnessSurface roughness defects. This paper explores both traditional fracture mechanicsFracture mechanics tools and modificationsModification to crackCrack growth algorithms by correcting for small crackCrack effects using an in-house developed crackCrack growth code. Three modificationsModification are explored and compared: (1) addition of a small material dependent increment to the crackCrack length, (2) addition of the cyclic plastic zone size to the crackCrack length, and (3) elimination of crackCrack closure effects for small cracksCrack. FatigueFatigue lives of test coupons are calculated based on the maximum pit depth of the as-built surface and compared against fatigueFatigue test results from literature.