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Experimental Optimization for Fatigue Life Maximization of Additively Manufactured Ti-6Al-4V Alloy Employing Ultrasonic Impact Treatment

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Abstract

Ultrasonic Impact Treatment (UIT) is an effective surface modification method used to increase fatigue life of welding application by inducing compressive residual stresses. In this paper, we extend the application of UIT to include additively manufactured metallic parts with particular focus on Ti-6Al-4V manufactured with Direct Metal Laser Sintering technology. Design optimization for the application parameters of the UIT was conducted with the objective of fatigue life maximization. Application parameters of the UIT included the static pre-stressing force of UIT impact needle against the treatment surface and its scanning speed during application while the scanning pattern is maintained constant. Results show that a static load of 30N and a scanning speed of 2000mm/min can provide an optimal fatigue life increase up to 250% compared to untreated parts. It is shown that the increase in fatigue performance correlates strongly with an increase in the micro-hardness and compressive residual stress and less strongly with surface roughness. Two Stress-Life (S-N) curves are fully characterized experimentally based on a set of samples treated with the determined optimal UIT parameters and another set of untreated versions. Endurance limit of the optimally treated specimens is increased by 25% from about 200-250MPa.

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source (b) ultrasonic generator (c) impact tool (d) impact needle

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Abbreviations

UIT:

Ultrasonic Impact Treatment

AM:

Additively Manufactured

DMLS:

Direct Metal Laser Sintering

UIP:

Ultrasonic Impact Peening

SEM:

Scanning Electron Microscope

LPB:

Low Plasticity Burnishing

UNSM:

Ultrasonic Nanocrystal Surface Modification

HIP:

Hot Isostatic Pressing

TIG:

Tungsten Inert Gas

EDM:

Electro-Discharge Machining

TEM:

Transmission Electron Microscope

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Acknowledgments

Professor Mostafa S.A. ElSayed acknowledges the financial support provided by BOMBARDIER Aerospace of Montreal, in collaboration with CARIC National Forum (Grant No. CARIC-CRIAQ MDO-1601_TRL4+) and MITACS Canada (grant number IT07461). The authors would like to extend their acknowledgements to the employees of the machine shop, and Professor Dix of the X-Ray Diffractometry Lab, both at Carleton University for their guidance and patience, the Centre of Photonics Research and Dr. Jeff Ovens at the X-ray Core Facility, both at the University of Ottawa for their training and assistance. We wish also to acknowledge Mr. Leo Kok of Bombardier Aerospace for his continuous support and guidance. No competing financial interests exists between the authors and collaborators.

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  1. Mechanical and Aerospace Engineering, Carleton University, 1125 Colonel By Dr., Ottawa, ON, K1S 5B6, Canada

    Eric Trudel, Peter Walker, Shaza Nosir & Mostafa S. A. ElSayed

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  1. Eric Trudel
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Trudel, E., Walker, P., Nosir, S. et al. Experimental Optimization for Fatigue Life Maximization of Additively Manufactured Ti-6Al-4V Alloy Employing Ultrasonic Impact Treatment. J. of Materi Eng and Perform 30, 2806–2821 (2021). https://doi.org/10.1007/s11665-021-05576-9

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