Residual Stress Distribution and Its Effect on Fatigue Crack Path of Laser Powder Bed Fusion Ti6Al4V Alloy

Residual stress (RS) in laser powder bed fusion (LPBF) additive manufactured structures can significantly affect mechanical performance, potentially leading to premature failure. The complex distribution of residual stresses, combined with the limitations of full-field measurement techniques, presents a substantial challenge in conducting damage tolerance analyses of aircraft structures. To address these challenges, this study developed a comprehensive simulation framework to analyze the 3D distribution of residual stresses and fatigue crack growth in LPBF parts. The 3D residual stress profiles of as-built samples in 15° and 75° build directions were computed and compared to experimental data. The fatigue crack propagation behavior of the 75° sample, considering 3D residual stress, was predicted, and the effects of residual stress redistribution under cyclic loading were discussed. It shows that the anisotropy of residual stress, influenced by the build direction, can lead to mixed-mode fracture and subsequent crack deflection. Tensile residual stress in the near-surface region and compressive stress in the inner region can cause an inverted elliptical crack front and accelerate fatigue crack growth.