基于裂纹萌生与扩展的选区激光熔化Al-Mg-Sc-Zr合金疲劳寿命分析

doi:10.7527/S1000-6893.2025.31717

Abstract

Abstract:

Additive Manufacturing （AM） has significant application value in the aerospace field due to its characteristics of free-forming and rapid production. However， the fatigue dispersion of materials produced by AM shows considerable variability， making accuratel fatigue life assessment a key challenge in aerospace applications. Selective Laser Melting （SLM） Al-Mg-Sc-Zr alloy exhibits high strength and low density. This paper establishes a fatigue life analysis method based on the mechanisms of crack initiation and propagation for this material. First， a rapid Stress Intensity Factor （SIF） analysis model was developed for cracks with varying sizes and locations based on finite element analysis. Subsequently， the crack propagation life was evaluated using the NASGRO model， and a defect-based crack initiation life model was established. Ultimately， a two-stage fatigue life analysis encompassing both crack initiation and propagation was developed. The analysis results were compared with fatigue test data from Transverse Build Direction （TD） and Parallel Build Direction （PD） samples. The results indicate that the fatigue life text results generally fall within the twofold error band， validating the effectiveness of the proposed method. Crack initiation is primarily influenced by the defect geometric characteristics， while crack propagation is mainly governed by the microstructure. This method provides a scientific basis and means for fatigue life assessment of AM materials.

Key words: selective laser melting, Al-Mg-Sc-Zr, crack initiation and propagation, defect geometric characteristics, life analysis

CLC Number:

V215.6

Jun ZOU, Zhuyi CHEN, Xiaoyu XIA, Zhenyu FENG. Fatigue life analysis of selective laser melting Al-Mg-Sc-Zr alloy based on crack initiation and propagation[J]. Acta Aeronautica et Astronautica Sinica, 2025, 46(17): 431717.

Figures/Tables 16

Fig.1

Fig.2

Table 1

Fatigue test results and geometry characteristics of critical defects

编号	$σ a$ /MPa	area^1/2/μm	area $e f f 1 / 2$ /μm	裂纹源位置及类型	l/μm	缺陷圆度	$θ$ /（°）	疲劳寿命/cycle
TD 1^#	121.50	76.40	78.94	表面未熔合	38.04	0.58	61.6	1 472 168
TD 2^#	135.00	47.84	53.74	表面未熔合	39.55	0.18	69.0	115 891
TD 3^#	135.00	70.15	90.82	表面未熔合	58.8	0.21	74.6	49 841
TD 4^#	148.50	55.50	55.50	表面未熔合	30.16	0.39	53.0	441 839
TD 5^#	148.50	68.76	72.30	内部气孔	2 314.39	0.47	77.1	1 950 776
TD 6^#	148.50	45.71	50.82	表面未熔合	22.13	0.34	61.9	444 394
TD 7^#	162.00	54.95	60.14	表面未熔合	42.15	0.47	79.0	24 470
TD 8^#	162.00	120.60	123.03	表面未熔合	49.92	0.61	44.4	19 174
TD 9^#	162.00	61.13	77.81	表面未熔合	44.59	0.25	56.4	26 455
TD 10^#	175.50	51.15	52.03	表面未熔合	31.12	0.64	63.7	24 658
TD 11^#	175.50	41.24	42.31	表面未熔合	17.87	0.3	44.3	17 477
TD 12^#	175.50	54.76	62.12	表面未熔合	19.74	0.36	34.6	21 974
PD 1^#	135.00	116.38	131.30	表面未熔合	36.47	0.37	11.0	37 422
PD 2^#	135.00	113.90	128.43	内部未熔合	451.04	0.71	74.8	655 162
PD 3^#	148.50	67.74	80.30	表面未熔合	37.51	0.45	49.5	69 799
PD 4^#	148.50	74.96	88.73	表面气孔	34.91	0.6	82.7	102 889
PD 5^#	148.50	40.73	44.09	表面未熔合	10.56	0.19	2.8	179 919
PD 6^#	148.50	117.51	131.85	内部未熔合	746.69	0.69	58.6	841 592
PD 7^#	155.25	63.13	72.09	表面未熔合	26.55	0.29	15.2	71 272
PD 8^#	155.25	41.46	65.18	表面气孔	25.08	0.26	25.1	95 560
PD 9^#	155.25	119.02	121.91	内部气孔	1 100.16	0.56	81.2	553 775
PD 10^#	162.00	53.98	67.60	表面气孔	32.37	0.46	54.3	42 178
PD 11^#	162.00	79.04	87.20	表面未熔合	35.13	0.43	54.7	31 337
PD 12^#	162.00	100.47	104.67	内部未熔合	408.81	0.69	37.8	398 848
PD 13^#	168.75	112.83	118.06	内部未熔合	589.8	0.67	67.5	349 802
PD 14^#	168.75	66.87	77.62	表面气孔	27.58	0.35	28.8	26 326
PD 15^#	175.50	84.09	91.45	内部未熔合	853.33	0.48	69.9	466 572
PD 16^#	175.50	62.75	71.14	表面未熔合	45.27	0.39	79.3	34 094

Table 1

Fig.3

Table 2

Correlation coefficients between influencing factors and fatigue life

方向	σ_a	L	area^1/2	S	$φ$
TD	-0.517	0.761	0.143	0.310	0.373
PD	-0.178	0.850	0.682	0.701	0.406

Table 2

Fig.4

Fig.5

Fig.6

Table 3

Fig.7

Fig.8

Table 4

Fig.9

Fig.10

Fig.11

Fig.12

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方向	p	m	q	C/10^-6
TD	0.41	2.15	0.20	1.60
PD	1.45	1.81	0.52	4.48

方向	Z参数模型	X参数模型	F参数模型	改进F参数模型
TD	0.74	0.77	0.82	0.90
PD	0.75	0.81	0.92	0.90

Fatigue life analysis of selective laser melting Al-Mg-Sc-Zr alloy based on crack initiation and propagation

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