Fatigue properties of Laser Powder Bed Fusion (LPBF) built 21-6-9 stainless stee

Abstract: Fatigue performance is one of the important mechanical properties which is hindering some of the additive manufacturing build structures. The main objective of this study is to investigate the fatigue life dependence of the 21-6-9 austenitic stainless-steel build using the laser powder bed fusion (LPBF) technique. The study is mainly focused on the fracture surface based on defects and the micro constituents, how they are related to the fatigue performance of the samples. 21 samples were build using optimized process parameters in which 9 of the samples were built-in vertical direction and the remaining 12 were built in the horizontal direction. Low cycle fatigue (LCF) testing was carried out with the samples with 2 conditions i.e., room temperature 24⁰C and 750 ⁰C. Before the specimens were subjected to testing the samples were stress relived at 600⁰C for 2 hours. Fractography was carried out on the fracture surface to pinpoint the initiation sites (concluded by analyzing the striations) and the cause of failure. Microstructural characterization was carried out in both the vertical and the horizontal direction of the build. The fatigue crack growth initiated from the surface where defects were present, when the cyclic loads were applied the stress concentration at these regions caused the crack initiation to take place. In some cases, the defect size was smaller at the initiation site, and that correlated to increased fatigue life. To optimize the fatigue life of LPBF built 21-6-9 is important to minimize the grain size. However, the absence of defects is crucial as well, as those typically are the weakest link. Therefore, minimizing those during the manufacturing is essential.