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Fatigue Crack Growth Behavior of AlSi10Mg Material Produced by Direct Metal Laser Sintering Using S-Version Finite Element Method

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Abstract

The researchers are becoming more interested in additive manufacturing (AM). This technology has numerous advantages, particularly in the aerospace, medical and automotive industries. Due to the limited integrity of AM materials, there is a need to do research on this manufacturing technology. The primary concern of engineering applications is a material failure. The fatigue crack growth rate of the AM material, AlSi10Mg, is determined using the S-version finite element method (FEM). The global–local technique was used in the S-version FEM, which consists of two meshes: global and local. S-version FEM concentrated exclusively on the superimposed local crack. The stress intensity factor (SIF) of the crack is calculated using the virtual crack closure method. The SIF value is critical because it has an effect on crack growth. The Newman and Raju (Eng Fract Mech 11(4):817–829, 1979. https://doi.org/10.1016/0013-7944(79)90139-5) equation was used to validate the S-version FEM result. It demonstrates poor agreement due to computational and meshing limitations.

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Acknowledgments

The author would like to acknowledge the Ministry of Higher Education under Fundamental Research Grant Scheme FRGS/1/2019/TK03/UMP/02/21 (university reference RDU1901151) and Universiti Malaysia Pahang (PGRS220386) for financial support. Also, the authors would like to thank UMP for allowing the research to be conducted using high-performance computer (HPC).

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Authors and Affiliations

  1. Faculty of Mechanical & Automotive Engineering Technology, University Malaysia Pahang, 26600, Pekan, Pahang, Malaysia

    F. Y. Chin, M. S. Shaari & M. R. M. Akramin

  2. Faculty of Science and Technology, Tokyo University of Science, 2641 Yamazaki, Noda-shi, Chiba-ken, Japan

    Akiyuki Takahashi

  3. Institut Latihan Perindustrian Kota Kinabalu, Kota Kinabalu, Sabah, Malaysia

    Sylvia Urai

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  1. F. Y. Chin
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Correspondence to M. S. Shaari.

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This article is an invited paper selected from presentations at the 6th Symposium on Damage Mechanism in Materials and Structures (SDMMS 2022), held August 16–17, 2022 in Kuantan, Malaysia. The manuscript has been expanded from the original presentation. The special issue was organized by Nasrul Azuan Alang, Norhaida Ab Razak, and Aizat Alias, Universiti Malaysia Pahang.

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Chin, F.Y., Shaari, M.S., Takahashi, A. et al. Fatigue Crack Growth Behavior of AlSi10Mg Material Produced by Direct Metal Laser Sintering Using S-Version Finite Element Method. J Fail. Anal. and Preven. 23, 601–608 (2023). https://doi.org/10.1007/s11668-023-01643-6

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