Journal article
Generalised notch stress method to evaluate the fatigue behaviour of rough and smooth wire arc additively manufactured components
- Abstract:
- The fatigue life of components under cyclic loading is highly sensitive to surface conditions, as imperfections lead to stress concentrations and early fatigue crack initiation. This study investigates the fatigue performance of both rough and smooth specimens made from S355 low-alloy carbon steel using a cold metal transfer (CMT)-based wire arc additive manufacturing (WAAM) process. Three types of specimens (machined, sinuous and raster specimens) with different surface geometries are fabricated. Rough fatigue coupons are cut using waterjet cutting from the as-deposited walls while keeping the rough surface unmachined. The geometric properties of rough fatigue coupons are quantified by a 3D laser scanner, followed by static tensile tests, hardness measurements and fatigue tests. Fatigue crack initiation and propagation for different surface types are analysed under scanning electron microscopy (SEM). Several computational methods, including the numerical local fatigue stress evaluation, the hot spot stress method and the effective notch stress method, are analysed for their effectiveness in assessing the fatigue resistance of rough specimens. A generalised notch stress method based on notch stress theory is proposed and validated. Our results prove that the fatigue performance of specimens with different surface conditions can be unified using the proposed generalised notch stress method.
- Publication status:
- Published
- Peer review status:
- Peer reviewed
Actions
Access Document
- Files:
-
-
(Preview, Accepted manuscript, pdf, 57.2MB, Terms of use)
-
- Publisher copy:
- 10.1016/j.ijfatigue.2025.109045
Authors
- Publisher:
- Elsevier
- Journal:
- International Journal of Fatigue More from this journal
- Volume:
- 199
- Article number:
- 109045
- Publication date:
- 2025-05-05
- Acceptance date:
- 2025-05-04
- DOI:
- EISSN:
-
1879-3452
- ISSN:
-
0142-1123
- Language:
-
English
- Keywords:
- Pubs id:
-
2122510
- Local pid:
-
pubs:2122510
- Deposit date:
-
2025-05-12
Terms of use
- Copyright holder:
- Elsevier Ltd.
- Copyright date:
- 2025
- Rights statement:
- © 2025 Elsevier Ltd. All rights are reserved, including those for text and data mining, AI training, and similar technologies.
- Notes:
-
The author accepted manuscript (AAM) of this paper has been made available under the University of Oxford's Open Access Publications Policy, and a CC BY public copyright licence has been applied.
This is the accepted manuscript version of the article. The final version is available online from Elsevier at https://dx.doi.org/10.1016/j.ijfatigue.2025.109045
- Licence:
- CC Attribution (CC BY)
If you are the owner of this record, you can report an update to it here: Report update to this record