High cycle fatigue performance evaluation of a laser powder bed fusion manufactured Ti-6Al-4V bracket for aero-engine applications

Due to the stringent certification requirements and complex engine operating environment, the design of AM components for aero-engine application remains a challenging task. The high cycle fatigue performance of a weight-optimised bracket made using the Laser Powder Bed Fusion (LPBF) process was studied through shaker table testing. The results are discussed together with the observed mechanical and fatigue strengths in conjunction with material characterisation of microstructure, surface roughness, defects, micro-hardness and fracture surfaces. The debits in mechanical and fatigue strengths are expected due to process dependent surface roughness and the density of defects present. From the shaker table test results, it was concluded that the proposed weight-optimised LPBF bracket is capable of meeting the performance targets. The fundamental vibration mode of the bracket assembly was 84 Hz, which was much higher than the 1st Low Pressure shaft speed (48 Hz) of the target engine and thus avoids potential resonance. The bracket achieved its target inertial g load capability of 20 g and it was demonstrated that the bracket had enough redundancy in its load transfer paths should a strut fail during service of the engine. Lack of fusion voids and micro-cracks present on or near the surface were the prime sites for crack initiation. It has been shown that the as-built surface can cause a significant reduction (up to 40%) in the fatigue strength when compared to machined Ti-6Al-4V. A safe life regime for LPBF component design has been presented based on the Kitagawa-Takahasi diagram, modified using the Chapetti curve, which effectively links the material fatigue properties and performance of LPBF parts with intrinsic defects.