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High and very high cycle fatigue behavior of an additive manufactured hot-work tool steel
Karlstad University, Faculty of Health, Science and Technology (starting 2013), Department of Engineering and Physics (from 2013).ORCID iD: 0009-0001-6982-3625
Karlstad University, Faculty of Health, Science and Technology (starting 2013), Department of Engineering and Physics (from 2013).ORCID iD: 0000-0001-5140-9074
Karlstad University, Faculty of Health, Science and Technology (starting 2013), Department of Engineering and Physics (from 2013).ORCID iD: 0000-0001-6029-2613
Karlstad University, Faculty of Health, Science and Technology (starting 2013), Department of Engineering and Physics (from 2013).ORCID iD: 0000-0002-4289-6154
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2024 (English)In: Materials Science & Engineering: A, ISSN 0921-5093, E-ISSN 1873-4936, Vol. 917, article id 147401Article in journal (Refereed) Published
Abstract [en]

In the present study, the fatigue response of an additive manufactured H13 type hot-work tool steel is investigated across the High Cycle Fatigue (HCF) and Very High Cycle (VHCF) regimes. The primary focus encompasses the interpretation of fatigue strength models, the defect type analysis along with a detailed examination of crack initiation and growth mechanisms. Despite the tremendous development in AM technology, experimental data regarding advanced mechanical properties, and particularly fatigue behavior, are still limited. Here, microstructural analysis of a modified AMed H13 hot-work tool steel, a combination of HCF and VHCF testing methodologies implemented for the characterization of the fatigue behavior, as well as a thorough fractographic analysis of the fractured surfaces were performed. Results are compared with historical data of a conventionally ingot cast and forged grade to assess the influence of the AM process on the fatigue response of H13 hot-work tool steels. It proves to be comparable to the conventionally manufactured grade, showcasing the potential utilization of AM in the production of components used in high-demanding applications, and in hot work tooling applications. However, the type of critical defects identified in the AM grade was found to be process-induced, emphasizing the need to optimize process parameters to reduce both the number and size of defects and also to ensure component reliability and high performance in various industrial applications. 

Place, publisher, year, edition, pages
Elsevier, 2024. Vol. 917, article id 147401
Keywords [en]
Fatigue crack, Fatigue testing, Fracture testing, High-cycle fatigue, Low-cycle fatigue, Metal working tools, Steel ingots, Steel testing, Thermal fatigue, AM h13 hot-work tool steel, Cycle fatigue behaviors, Fatigue behaviour, Fatigue response, Fatigue strength, High cycle, High cycle fatigue, Hot-work tool steel, Strength models, Very-High-Cycle Fatigue, Bessemer process
National Category
Materials Engineering
Research subject
Materials Engineering; Mechanical Engineering; Mechanical Engineering
Identifiers
URN: urn:nbn:se:kau:diva-102151DOI: 10.1016/j.msea.2024.147401ISI: 001339964900001Scopus ID: 2-s2.0-85206614024OAI: oai:DiVA.org:kau-102151DiVA, id: diva2:1910681
Funder
Knowledge Foundation, 20190033Available from: 2024-11-05 Created: 2024-11-05 Last updated: 2025-10-30Bibliographically approved
In thesis
1. Fatigue, defects and failure mechanisms in high strength tool steels at different fatigue life regimes
Open this publication in new window or tab >>Fatigue, defects and failure mechanisms in high strength tool steels at different fatigue life regimes
2024 (English)Licentiate thesis, comprehensive summary (Other academic)
Abstract [en]

Fatigue response of metallic materials is considered of significant importance, particularly for high-demanding applications. It is proved that most of the engineering materials do not exhibit a conventional fatigue limit in the high cycle fatigue regime, but rather display a continuously decreasing stress-life response at even longer lifetimes. Consequently, investigations of the various failure mechanisms taking place are essential, especially at the high and very high cycle fatigue regimes.The development of new ultrasonic testing equipment made the fatigue testing beyond 107 life cycles possible in a much shorter time, enabling testing with fatigue fractures at stress levels lower than the traditionally proposed “fatigue limit”. Nowadays, a classification of fatigue life regimes in Low Cycle Fatigue (LCF), High Cycle Fatigue (HCF) and Very High Cycle Fatigue (VHCF) is commonly used. The main reasons for this specific grading are: i) the need for safe design of components and ii) the fact that the failure mechanisms are particular in each of the LCF, HCF and VHCF regimes.The main goal of the present thesis is to address the fatigue response of high strength tool steels. Considering the novel alterations in composition and production methods in alloy development, materials of high-quality are continuously being introduced to the market; understanding the fatigue response of these materials is crucial for potential utilization across diverse industries and applications. The generation of fatigue experimental data, the analysis of the different types of fatigue initiation defects found in each material, as well as the investigation of the fatigue mechanisms occurring during cyclic loading are the main subjects analyzed throughout the present study. 

Abstract [sv]

Utmattningsegenskaper hos metalliska material anses vara av stor betydelse, särskilt för krävande tillämpningar. Det är visat att de flesta konstruktionsmaterial inte uppvisar en konventionell utmattningsgräns i området för högcykelutmattning, utan snarare uppvisar ett kontinuerligt minskande spänning-livslängd förhållande med längre livslängder. Följaktligen är undersökningar av de olika brottmekanismer som äger rum väsentliga, särskilt vid utmattningsregimer med höga och mycket höga livslängder.Utveckling av nya ultraljudsutrustningar gjorde utmattningsprovning utöver 107 livscykler möjliga på mycket kortare tid, vilket möjliggjorde provning med utmattningsbrott vid längre livstid och spänningsnivåer lägre än den traditionellt föreslagna "utmattningsgränsen". Nuförtiden används en indelning av utmattningsregimer i lågcykelutmattning (Low Cycle Fatigue LCF), högcykelutmattning (High Cycle Fatigue HCF) och utmattning vid mycket långa livslängder (Very High Cycle Fatigue VHCF). De huvudsakliga skälen till denna indelning är: i) behovet av säker design av komponenter, och ii) det faktum att brottmekanismerna är speciella i var och en av LCF-, HCF- och VHCF-regimerna. Det främsta målet med denna avhandling är att adressera utmattningsegenskaper hos höghållfasta verktygsstål. Med tanke på nya sammansättningar och produktionsmetoder i legeringsutvecklingen introduceras material av hög kvalitet kontinuerligt på marknaden; att förstå utmattningsresponsen hos dessa material är avgörande för potentiella användningar inom olika industrier och applikationer. Genereringen av experimentell utmattningsdata, analysen av de olika typerna av initieringsdefekter som hittats i varje material, såväl som undersökningen av utmattningsmekanismerna som uppstår under cyklisk belastning är huvudämnena som analyseras genom hela denna studie.

Place, publisher, year, edition, pages
Karlstads universitet, 2024. p. 34
Series
Karlstad University Studies, ISSN 1403-8099 ; 2024:13
National Category
Materials Engineering
Research subject
Materials Engineering
Identifiers
urn:nbn:se:kau:diva-99279 (URN)10.59217/fvip8564 (DOI)978-91-7867-455-8 (ISBN)978-91-7867-456-5 (ISBN)
Presentation
2024-06-13, 11D121, Andersalen, 09:15 (English)
Opponent
Note

Paper 2 part of thesis as manuscript, now published.

Available from: 2024-05-28 Created: 2024-04-09 Last updated: 2025-10-30Bibliographically approved
2.
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Chantziara, KaterinaNikas, DimitriosBergström, JensGrehk, Mikael

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