Experimental investigation of fatigue crack growth in wire arc additively manufactured ER2209 duplex stainless steel
File(s)
Published version
Author(s)
Chen, Man-Tai
Chen, Yangyu
Huang, Cheng
Gardner, Leroy
Zhao, Ou
Type
Journal Article
Abstract
This study investigates the fatigue crack growth (FCG) behaviour of ER2209 duplex stainless steel produced using wire arc additive manufacturing (WAAM). The effects of minimum-to-maximum load ratio (R = 0.1, 0.3, 0.5), loading direction (θ = 0°, 30°, 45°, 60°, 90°) and surface condition (as-built or milled) of the WAAM specimens on the FCG performance have been studied by means of 11 compact tension (CT) tests. The design, manufacture and fatigue testing of the specimens are described, followed by a discussion of the test results, including the Paris' law material constants, fatigue crack growth rates (FCGR) and crack trajectories. The test results showed that the FCGR increased with increasing load ratios. The effect of loading direction (i.e. anisotropy) on the measured FCG behaviour was found to be minimal. The FCG behaviour of the studied WAAM ER2209 duplex stainless steel was shown to be superior to that of conventionally-produced duplex stainless steel, while similar FCG behaviour was observed for the milled and as-built specimens. The observed FCGR behaviour was shown to be conservatively predicted by the provisions in two current standards — BS 7910 and IIW-1823-07. Macroscopic and microscopic fractographic analysis of typical CT specimens was undertaken, revealing transgranular fracture as characterised by numerous fatigue striations, secondary cracks and dimples.
Date Issued
2025-08-01
Date Acceptance
2025-04-26
Citation
Journal of Constructional Steel Research, 2025, 231
ISSN
0143-974X
Publisher
Elsevier
Journal / Book Title
Journal of Constructional Steel Research
Volume
231
Copyright Statement
© 2025 The Authors. Published by Elsevier Ltd. This is an open access article under the CC BY license (http://creativecommons.org/licenses/by/4.0/)
License URL
Identifier
10.1016/j.jcsr.2025.109615
Publication Status
Published
Article Number
109615
Date Publish Online
2025-05-02