Fracture mechanics-based approach for anomaly size acceptability of additively manufactured metals

icaf2023 Tracking Number 133

The traditional approach for quantifying material capability generally assumes that material properties in components are fully represented by test bar results. However, this assumption might not always be true for complex additively manufactured components, which may contain anomaly populations different than those expected based on relatively simple-geometry mechanical test coupons. In this work, we present a possible fracture mechanics-based approach for definition of anomaly size acceptability limits for AM materials, to augment the traditional building block of fatigue test-based material capability assessments. The fracture mechanics analysis is validated against fractography observations of tested bars and with fatigue tests on bars containing artificially notched coupons.