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Experimental Investigation of Fretting Fatigue of Titanium Specimens Made by Additive Manufacturing Method

Sajjad Houshmand | 2024

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  1. Type of Document: M.Sc. Thesis
  2. Language: Farsi
  3. Document No: 57353 (45)
  4. University: Sharif University of Technology
  5. Department: Aerospace Engineering
  6. Advisor(s): Adibnazari, Saeed
  7. Abstract:
  8. Additive manufacturing (AM) has gained significant attention in recent years as a novel approach to fabricate three-dimensional parts. Its advantages, including high speed, low-cost production for small-scale batches, and greater design freedom, have made it a competitive alternative to traditional manufacturing methods. However, the application of AM for components subjected to fretting fatigue requires careful evaluation. Fretting fatigue is a major cause of failure in turbines, particularly at the contact interface between turbine blade roots and disk. In this study, the influence of AM and post-processing treatments on the fretting fatigue life of Ti-6Al-4V alloy was investigated. Five standard coupon specimens made of Ti-6Al-4V alloy were fabricated using selective laser melting (SLM) and subjected to fretting fatigue tests under various loading conditions. The results indicated that the fretting fatigue life of AM-produced specimens was approximately 50% lower than that of conventionally manufactured specimens. Additionally, it was observed that heat treatment and surface finishing up to mirror polishing could significantly enhance fretting fatigue life by up to 6 times in some cases. The reduced fretting fatigue life and fatigue strength in these specimens can be attributed to defects induced during the AM process, such as porosity, lack of fusion between metal powder particles, and material discontinuity. Heat treatment, surface finishing, and precise control of manufacturing parameters can effectively mitigate some of these defects and improve fatigue life. Despite the remarkable advantages of AM, its industrial application for components subjected to fretting fatigue demands more rigorous evaluation and further testing
  9. Keywords:
  10. Fretting Fatigue ; Additive Manufacturing ; Titanium Alloy 6AL-4V ; Heat Treatment ; Electron Beam Melting (EBM) ; Selective Laser Melting (SLM)

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