Analytical Prediction of Fatigue Resistance of Additively Manufactured Aluminium Alloy Based on Murakami Method

Nik Nur Khaleeda Nik Nor Zainal Abidin; Matthias  Oberreiter; Michael  Stoschka; Yupiter  HP Manurung; Mohd Shahriman Adenan; Renga Rao  Krishnamoorthy

doi:10.24191/jaeds.v3i2.66

Authors

Nik Nur Khaleeda Nik Nor Zainal Abidin School of Mechanical Engineering, Universiti Teknologi MARA, Shah Alam 40450 Selangor, Malaysia.
Matthias Oberreiter Chair of General Mechanical Engineering, Montanuniversität Leoben, 8700, Austria
Michael Stoschka Chair of General Mechanical Engineering, Montanuniversität Leoben, 8700, Austria
Yupiter HP Manurung Smart Manufacturing Research Institute, Universiti Teknologi MARA, Shah Alam 40450 Selangor, Malaysia
Mohd Shahriman Adenan Smart Manufacturing Research Institute, Universiti Teknologi MARA, Shah Alam 40450 Selangor, Malaysia
Renga Rao Krishnamoorthy Smart Manufacturing Research Institute, Universiti Teknologi MARA, Shah Alam 40450 Selangor, Malaysia

DOI:

https://doi.org/10.24191/jaeds.v3i2.66

Keywords:

Murakami, Fatigue Strength, Stress Intensity Factor, ImageJ

Abstract

This research is devoted to analyze the stress state and fatigue strength on two different specimens made of aluminium alloy which was generated by using wire arc additive manufacturing (WAAM). The relationship between fatigue strength and flaw size was calculated based on the root squared area – a parameter by conventional Murakami’s equation which is a widely used analytical approach for predicting fatigue resistance in metallic materials. The research starts with the metallographic preparation process on two test series followed by Vickers hardness measurement. Further, the image of observed pores was to be processed and dimensioned using open-sourced software ImageJ by considering pixels and actual distance as well as by defining image threshold value for measuring pore sizes. The analytical approach is conducted in order to describe the maximum stress intensity factor Kmax at the crack front and to assess the fatigue strength σFS. As final results, specimen A has average pore area of ≈65 µm with Kmax of 333.75 MPa∙√m and σFS of 137 MPa, while specimen B has average pore area of ≈42 µm with Kmax of 325.13 MPa∙√m and σFS of 153 MPa. Overall, this research allows the formulation of a method for estimating fatigue strength of large defects leading to a conclusion that flaws can influence the fatigue resistance of the material so that the bigger the flaw size is, the lower σFS and the higher Kmax.

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