| Abstract: | Selective laser melting (SLM) was used to prepare notched high‐cycle fatigue test specimens made from nickel‐based superalloy Inconel 718. Samples were designed to have 1 of 3 different notch geometries, including V notches with Kt of 2.2 or 3.1, a U notch with Kt of 2.0, and were printed in either vertical or horizontal orientations. Samples were tested with as‐printed dimensions and surfaces after heat treatment, but a separate set of SLM samples were printed as plates and machined to final dimensions comporting to the V‐notch specimen with Kt = 3.1. High‐cycle fatigue testing showed that machined SLM specimens behaved similar to wrought Inconel 718 plate specimens, but testing with as‐produced surfaces led to a decrease in fatigue life. The explanation for this difference is based on approximations of linear elastic fracture mechanics solutions for short cracks emanating from notch roots, with intrinsic surface features of SLM materials serving as the cracks. Analysis of the actual notch geometries after SLM fabrication indicates that stress intensity in the presence of these features plays a prominent role in determining number of cycles before fatigue crack initiation and propagation occurs. |
