Defects in Electron Beam Melted Ti-6Al-4V: Fatigue Life Prediction Using Experimental Data and Extreme Value Statistics.

Electron beam melting is a powder bed fusion (PBF) additive manufacturing (AM) method for metals offering opportunities for the reduction of material waste and freedom of design, but unfortunately also suffering from material defects from production. The stochastic nature of defect formation leads to a scatter in the fatigue performance of the material, preventing wider use of this production method for fatigue critical components. In this work, fatigue test data from electron beam melted Ti-6Al-4V specimens machined from as-built material are compared to deterministic fatigue crack growth calculations and probabilistically modeled fatigue life.