Ecm Titanium 1.61 Crack 107
Crack 107 was easily apparent in the as-received material, and exhibited a very irregular morphology ( Figure 4a). The fracture surface was not smooth, but exhibited features that were parallel to the loading direction. This fracture morphology is not typical for ductile material and is often indicative of SLC. This crack was initiated with a 5.
Porosity and microstructure play an important role in fatigue crack growth. A high porosity is detrimental for fatigue life. Microstructure with a severe dislocation density gradient tends to be more fatigue resistant than a homogeneous microstructure. Reduction in peak stress by crack size reduction has been reported [4 ]. In the case of Ti-6Al-4V with a relatively coarse grain microstructure, after an initial increase in fatigue life with increasing defect size, the fatigue life begins to decrease with increasing defect size above 40 μm in critical dimensions 4 .
Fatigue crack growth is a complex process with the microstructure, stress history and crack growth rate all playing significant roles in the survival of the fatigue life. Apart from the EBM process itself, titanium alloys can be manufactured with a range of different microstructures by selecting alloying elements with different segregation behaviour. In general, the failure mechanism for fatigue is characterized by: crack initiation, crack propagation and crack arrest. Fatigue crack growth begins with initiation at pre-existing damage, usually microdefects and at grain boundaries and propagates through the material until damage accumulation becomes excessive at crack tips [19] . Crack propagation through the material can be controlled by the preferential movement of dislocations in either the glide or climb directions [20] . Crack arrest is usually the result of a competition between crack and dislocation glide during the crack growth process, where either type of dislocation leads to crack arrest [20] . Figure 5 shows the effect of different plastic deformation mechanisms on fatigue crack growth for a reference 2% proof stress of 180MPa. The values used for grain size and dislocation density are based on those shown in the simulation results and reflect the microstructural parameters found in industry components. In the case of the reference material, only dislocation glide is observed and, consequently, crack propagation is limited by the availability of dislocation glide planes in the material. If fatigue cracks are initiated at the boundaries and cracks grow through the microstructure at uniform speed, the fatigue life is predicted to be limited to about 100 cycles. The onset of fatigue crack initiation is observed in the simulation when the maximum crack advance rate has reached 1μm/cycle. Under these conditions, the fatigue life is predicted to be roughly 10,000 cycles.
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