Early Damage Evolution and Lifetime Prediction of Wire Arc Additive Manufactured Nickel Aluminum Bronze through High-Throughput Ultrasonic Fatigue Testing: An In-situ Corrosion Fatigue Study
Abstract
The proposed project investigates the early damage evolution and lifetime prediction of wire arc additive manufactured (WAAM#d) nickel aluminum bronze (NAB) in an in-situ corrosion condition employing high-throughput ultrasonic fatigue (USF) testing. The aim is to understand the mechanical (cyclic) failure of NAB in corrosive environments and provide valuable insights into the potential use of the WAAM#d NAB for high-demand long-term applications in U.S. Navy. We want to gain an advanced understanding of the influence ofvarious factors (i.e., stress amplitude, corrosion environment, microstructure, and WAAM-induced defects) on the long- and ultralong-life fatigue performance employing a high-throughput fatigue data generation approach.To achieve this goal, a novel high-throughput corrosion USF testing, in an in-situ corrosive environment, will be utilized. The proposed methodology will involve the use of a specific custom-built corrosion cell capable of performing a high and very high number of cycles (i.e., 10^5 to 10^9) of loading cycles simultaneously under controlled conditions, enabling rapid data acquisition. To this end, the ultrasonic corrosion fatigue tests will be conducted in a synthetic saline solution (A3 synthetic seawater), simulating the in-service conditions of marine environments. The reason for using the A3 synthetic water, being more saline than actual seawater, is to hasten the corrosion process and to counterbalance the high frequency (i.e., 20,000 Hz) of the USF tests. Employing the proposed technique, we can also quantify the extended (ultralong) corrosion fatigue life of WAAM NAB (i.e, number of cycles to failure, Nf, beyond 10 million cycles) in a feasible and reasonable testing time frame.The proposed project also explores the potential of USF for lifetime prediction. The data obtained from the high-throughput tests will be employed to develop a fatigue life prediction model for WAAM NAB in a corrosive environment. The model considers the effects of corrosion on the material s mechanical properties, including the reduction in fatigue life and the changes in crack initiation behavior. The model can be used as a tool to predict the fatigue life of WAAM NAB under different loading conditions and in corrosive environments.We expect the WAAM NAB to show a distinctively different fatigue behavior compared to conventional wrought/cast counter material due to characteristically different solidification rates and microstructural and defect features between conventionally and WAAM NAB. We expect the fatigue strength of NAB to be adversely affected by the corrosive environment. The in-situ corrosion shall accelerate the crack initiation and propagation, leading to shorter fatigue life.The outcomes of this research will provide valuable insights into the mechanisms governing the corrosion fatigue behavior of WAAM NAB, which can be used to optimize its performance in various industrial applications. The findings of this study are relevant for U.S. Navy applications, where the material is exposed to harsh marine environments. The long-term goal of the research is to develop scaling relationships that enable high-frequency measurements to be used in lower-frequency applications, which will greatly accelerate the qualification of new alloys for fatigue-sensitive naval applications.Considering the educational and outreach activities, our primary goals are to increase participation in science, technology, engineering, and math (STEM) careers among female students and students of color by establishing the Transformative Education in Additive Manufacturing Systems (TEAMS) program for grade 9#12 African Americans in Additive Manufacturing (A3M) education by hosting a one-week long 3D printing workshop, in summers 2024 and 2025, at our Fatigue Research Lab. for high school girls and students of color selected by the Center for Racial Equity and Black Student Excellence at the University of Toledo.
Document Details
- Document Type
- DoD Grant Award
- Publication Date
- Aug 11, 2023
- Source ID
- N000142312798
Entities
People
- Meysam Haghshenas
Organizations
- Office of Naval Research
- United States Navy
- University of Toledo