Research: Fatigue Crack Growth Behavior of Additively Manufactured Ti-6Al-4V Under Vari...

Research question: How do process-induced microstructural variations in additively manufactured Ti-6Al-4V influence fatigue crack initiation and growth rates under variable amplitude loading?

Titanium alloys such as Ti-6Al-4V are widely used in aerospace and biomedical applications due to their high strength-to-weight ratio and corrosion resistance. Additive manufacturing (AM) processes like selective laser melting (SLM) enable complex geometries but introduce unique microstructural features and potential defects affecting mechanical performance.

Despite extensive research on static properties, the fatigue and crack growth behavior of AM Ti-6Al-4V—especially under realistic loading—remains insufficiently characterized, with limited understanding of how process parameters and resulting microstructures impact fatigue resistance.

This project will systematically investigate fatigue crack initiation and growth rates in SLM-produced Ti-6Al-4V specimens, employing detailed fractography, microstructural analysis (SEM/EBSD), and variable amplitude fatigue testing. Results will be compared to wrought counterparts, and the influence of key AM process parameters will be analyzed using statistical methods.

Findings will inform design criteria, post-processing strategies, and qualification protocols for critical AM titanium components, advancing their safe adoption in high-performance engineering applications.