Abstract
The present study attempts to model the surface roughness of additive manufactured (AM) Inconel 718 (IN718) via the laser powder bed fusion (LPBF) process. A MATLAB code is developed to generate a rough surface, to match the experimental measurements of surface roughness after printing, grit blasting, and fine polishing (6, 2, and 0.5 µm Ra, respectively). Stress analysis carried out using ABAQUS and FE-Safe has been used to calculate and predict the fatigue life as a function of the roughness. LPBF IN718 samples are characterized for microstructure and mechanical properties to incorporate the room temperature material properties in simulation in the as printed and heat-treated condition. The surface microstructural features in the as-printed condition showed un-melted particles, contributing to high roughness values. Simulation can correlate the fatigue life to be inversely proportional to the surface roughness and establish that the stress gradient along the depth of a rough surface plays a crucial role in crack propagation. A sensitivity analysis has been carried out on the role of surface roughness to enable predicting the fatigue life in part geometries with inaccessible locations.
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Acknowledgements
The first author would like to acknowledge support from the Indian Institute of Technology, Ropar, during his M. Tech thesis.
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Kumar, S., Mahajan, D.K., Bouhattate, J. et al. An Experimentally Informed Computational Framework for Investigating the Role of Surface Roughness on High Cycle Fatigue Life of LPBF IN718. Trans Indian Natl. Acad. Eng. 8, 389–401 (2023). https://doi.org/10.1007/s41403-023-00405-y
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DOI: https://doi.org/10.1007/s41403-023-00405-y