An experimental study of residual stress and direction-dependence of fatigue crack growth behaviour in as-built and stress-relieved selective-laser-melted Ti6Al4V

Abstract Selective-laser-melting (SLM) is a powder-bed fusion additive-manufacturing process that has the potential to deliver three-dimensional complex parts with mechanical properties comparable or superior to parts produced via traditional manufacturing using cast and wrought alloys. Concerns for metallic parts built via SLM are the process-induced residual stresses, and anisotropic mechanical properties. This paper investigates the effect of residual stresses on the fatigue crack growth rate of SLM Ti6Al4V in as-built and stress-relieved conditions. Neutron diffraction and the contour method are employed to measure residual stresses in compact-tension samples. Neutron diffraction results are in good agreement with the contour method. It was found that tensile stresses are present at the notch root and the free edge areas, and compressive stress is seen in the middle of the sample. The tensile stresses in the as-built condition resulted in a higher fatigue crack growth rate. After stress relieving by heat treatment, the tensile residual stress diminished by around 90%, resulting in decreased crack growth rate. The build direction was seen to affect the crack growth rate, although the trend was different between the as-built and stress-relieved conditions.