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Lee, Seungjong; Pegues, Jonathan W.; Shamsaei, Nima
International journal of fatigue, December 2020, 2020-12-00, 20201201, 2020-12-01, Volume: 141, Issue: CJournal Article
Display omitted •Uniaxial strain- and force-controlled fatigue tests are conducted on LB-PBF 304L SS.•Specimens in machined/polished and as-built surface conditions are characterized.•Locational and directional effects on surface roughness of specimens are minimal.•The effect of surface roughness is more significant on stress-life behavior.•Fatigue life of as-built specimens can be estimated using their surface topography. The fatigue strength of additively manufactured metallic parts in their as-built surface condition is mainly dominated by the surface roughness. Post-processing is often inevitable to reduce surface roughness effects even though post-processing diminishes the main advantage of additive manufacturing, which is net-shaped direct-to-service production. This study investigates the underlying mechanisms responsible for fatigue failure of additively manufactured 304L stainless steel parts in as-built and machined/polished surface conditions. Both strain- and force-controlled, fully reversed fatigue tests were conducted to gain a comprehensive understanding of surface roughness effects on fatigue behavior. The sensitivity to surface roughness is shown to be dependent on the control mode, with stress-based fatigue tests showing greater sensitivity than strain-based fatigue tests. Moreover, the fatigue life estimation for as-built specimens was performed based on surface roughness parameters as well as the fatigue properties of the specimens in machined/polished surface condition of the material without using any fatigue data of specimens in as-built surface condition. Accordingly, the effect of surface roughness on the fatigue behavior could be estimated reasonably well in both strain-life and stress-life approaches.
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