High fatigue resistance in a titanium alloy via near-void-free 3D printing

Zhan Qu, Zhenjun Zhang (), Rui Liu, Ling Xu, Yining Zhang, Xiaotao Li, Zhenkai Zhao, Qiqiang Duan, Shaogang Wang, Shujun Li, Yingjie Ma, Xiaohong Shao, Rui Yang, Jürgen Eckert, Robert O. Ritchie () and Zhefeng Zhang ()
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Zhan Qu: Chinese Academy of Sciences
Zhenjun Zhang: Chinese Academy of Sciences
Rui Liu: Chinese Academy of Sciences
Ling Xu: Shenyang Institute of Engineering
Yining Zhang: Chinese Academy of Sciences
Xiaotao Li: Chinese Academy of Sciences
Zhenkai Zhao: Chinese Academy of Sciences
Qiqiang Duan: Chinese Academy of Sciences
Shaogang Wang: Chinese Academy of Sciences
Shujun Li: Chinese Academy of Sciences
Yingjie Ma: Chinese Academy of Sciences
Xiaohong Shao: Chinese Academy of Sciences
Rui Yang: Chinese Academy of Sciences
Jürgen Eckert: Austrian Academy of Sciences
Robert O. Ritchie: University of California Berkeley
Zhefeng Zhang: Chinese Academy of Sciences

Nature, 2024, vol. 626, issue 8001, 999-1004

Abstract: Abstract The advantage of 3D printing—that is, additive manufacturing (AM) of structural materials—has been severely compromised by their disappointing fatigue properties1,2. Commonly, poor fatigue properties appear to result from the presence of microvoids induced by current printing process procedures3,4. Accordingly, the question that we pose is whether the elimination of such microvoids can provide a feasible solution for marked enhancement of the fatigue resistance of void-free AM (Net-AM) alloys. Here we successfully rebuild an approximate void-free AM microstructure in Ti-6Al-4V titanium alloy by development of a Net-AM processing technique through an understanding of the asynchronism of phase transformation and grain growth. We identify the fatigue resistance of such AM microstructures and show that they lead to a high fatigue limit of around 1 GPa, exceeding the fatigue resistance of all AM and forged titanium alloys as well as that of other metallic materials. We confirm the high fatigue resistance of Net-AM microstructures and the potential advantages of AM processing in the production of structural components with maximum fatigue strength, which is beneficial for further application of AM technologies in engineering fields.

Date: 2024
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DOI: 10.1038/s41586-024-07048-1

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