Volume 46, Issue 1 pp. 153-170
ORIGINAL ARTICLE

Thermometric investigations for the characterization of fatigue crack initiation and propagation in Wire and Arc Additively Manufactured parts with as-built surfaces

Lorenzo Bercelli

Corresponding Author

Lorenzo Bercelli

ENSTA Bretagne, IRDL - UMR CNRS 6027, Brest, France

Correspondence

Lorenzo Bercelli, ENSTA Bretagne, IRDL - UMR CNRS 6027, 29200 Brest, France.

Email: [email protected]

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Cédric Doudard

Cédric Doudard

ENSTA Bretagne, IRDL - UMR CNRS 6027, Brest, France

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Sylvain Calloch

Sylvain Calloch

ENSTA Bretagne, IRDL - UMR CNRS 6027, Brest, France

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Vincent Le Saux

Vincent Le Saux

ENSTA Bretagne, IRDL - UMR CNRS 6027, Brest, France

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Julien Beaudet

Julien Beaudet

Naval Group Research, Technocampus Océan, 5 rue de l'Halbrane, Bouguenais, France

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First published: 02 October 2022

Funding information: “Self-Heating” ANR - Safran - Naval Group Research Chair, Grant/Award Number: ANR-20-CHIN-0002

Abstract

Metal Additive Manufacturing (AM) allows for the fabrication of complex shapes with high added value at low costs. Indeed, as-built structures are near net shape: they require few to no finishing operations. However, as-built AM parts present significant roughness caused by the layer discretization. In the case of the Wire and Arc Additive Manufacturing (WAAM) process, used for large-scale structures, the as-built roughness is estimated to several hundreds of micrometers. For complex geometries, a complete machining of the surfaces is not necessarily possible. In this study, an experimental method is proposed, relying on thermoelastic stress analysis, to characterize the effect of as-built WAAM surface roughness on high-cycle fatigue properties. Using an infrared camera, multiple cracks can be detected and monitored over a large surface on rough WAAM samples under cyclic bending. The collected data constitutes valuable information for the identification of a fatigue model dedicated to as-built WAAM structures.

DATA AVAILABILITY STATEMENT

Research data are not shared.

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