增材制造钛合金点阵超结构压缩疲劳断裂行为

doi:10.7527/S1000-6893.2025.32553

Abstract

Abstract:

Laser Powder Bed Fusion （LPBF） additively manufactured superstructures are highly promising for aerospace vehicles due to their excellent weight reduction performance and design flexibility， fulfilling the demand for high-performance， lightweight， and integrated components. However， surface roughness and internal porosity introduced by additive manufacturing tend to serve as initiation sites for fatigue cracks， potentially leading to premature failure of the lattice structures. To investigate effects of surface roughness and porosity on fatigue performance， Body Centered Cubic （BCC） lattice specimens were designed and fabricated by additive manufacturing. Fatigue tests under five different loading levels were conducted to obtain the corresponding Stress-Number of cycles （S-N） curves. A semi-empirical formula was used to calculate the stress concentration factor introduced by surface roughness. Additionally， the concept of effective load-bearing area was applied to account for the influence of both porosity and surface roughness. The accuracy of this method was verified through finite element simulations based on 3D reconstructed models， and the Neuber-Kuhn formula was used to estimate the fatigue limit. Based on the effective area correction， a fatigue S-N curve for a single strut was established， then a mapping method from the single-strut S-N curve to the lattice S-N curve was developed， and a corrected S-N curve was proposed. It is shown that the model incorporating effective load-bearing area correction more accurately reflects the coupled effect of surface roughness and internal porosity， and thereby it can improve the predictive accuracy of the fatigue limit and fatigue life of the lattice structures. The periodic boundary conditions in one unit lattice can be built and effectively simulate stress concentration in the whole structure. The corrected S-N curve is used to predict the fatigue life of the lattice， and its results fall within a scatter band of factor 3.

Key words: additive manufacturing, superstructure, surface roughness, pore, fatigue life

CLC Number:

V215.5

Wenbo SUN, Xuzhao DUAN, Ruiyang XU, Yu’e MA, Weihong ZHANG. Fatigue fracture behavior of additively manufactured titanium alloy superstructures under compressive loading[J]. Acta Aeronautica et Astronautica Sinica, 2026, 47(8): 432553.

Figures/Tables 30

Fig.1

Fig.2

Fig.3

Fig.4

Table 1

Chemical composition of TC4 alloy

元素	Ti	Al	V	Fe	C	H	O	N
含量/wt%	质量平衡	5.50~6.75	3.50~4.50	$≤$ 0.30	$≤$ 0.08	$≤$ 0.015	$≤$ 0.20	$≤$ 0.05

Table 1

Fig.5

Fig.6

Fig.7

Fig.8

Table 2

Fig.9

Fig.10

Fig.11

Fig.12

Table 3

Surface roughness parameters and stress concentration coefficient

路径	$R a$ /μm	$R y$ /μm	$R v$ /μm	$R z$ /μm	$R s m$ /μm	$ρ$ /μm	$K t$
1	36.65	224	120	148.0	333	67.87	2.73
2	27.39	219	118	149.0	313	59.63	2.62
3	19.71	182	68	133.6	278	46.19	2.57
4	18.35	182	65	137.0	263	47.69	2.48

Table 3

Fig.13

Fig.14

Fig.15

Fig.16

Fig.17

Fig.18

Fig.19

Table 4

Fatigue life test data of Ti-6Al-4V standard fatigue test piece

$S m a x$ /MPa	N/（10³ cycle）
500	137，62，106，184，295，194，216，273，190，182
550	31，44，94，127，224，60，83，94，71，65

Table 4

Fig.20

Fig.21

Fig.22

Fig.23

Table 5

Fig.24

Fig.25

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试验件编号	载荷/N	接触名义应力/MPa	疲劳寿命/ cycle
80-1	1 760	42.13	30 081
80-2			30 189
80-3			36 632
70-1	1 540	36.86	74 025
70-2			74 706
70-3			88 922
60-1	1 320	31.59	162 931
60-2			128 538
60-3			161 703
50-1	1 100	26.33	423 112
50-2			483 200
50-3			451 756
40-1	880	21.06	1 359 887
40-2			1 214 438
40-3			1 509 745

相对密度/%	接触面积/（10^-6 m²）	杆径/mm	结构应力集中系数
2.5	0.652 8	0.299	14.73
5.0	1.323 0	0.427	10.96
7.5	2.038 0	0.530	8.51
10.0	2.771 0	0.618	7.04
12.5	3.535 0	0.698	6.01
15.0	4.168 0	0.758	5.25
20.0	5.944 0	0.905	4.36

Fatigue fracture behavior of additively manufactured titanium alloy superstructures under compressive loading

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