Towards Deterministic Computation of Internal Stresses in Additively Manufactured Materials under Fatigue Loading: Part I.

The ongoing studies of the influence of internal defects on fatigue strength of additively manufactured metals adopted an internal crack or notch-like model at which the threshold stress intensity factor is the driving mechanism of fatigue failure. The current article highlights a shortcoming of this approach and offers an alternative based on X-ray microcomputed tomography and cyclic plasticity with a hybrid formulation of Chaboche and Armstrong-Frederick material laws. The presented tessellation and geometrical transformation scheme enabled a significantly more realistic morphological representation of internal defects that yielded a cyclic strain within 2% of the experimental values.