Research database

Lightweight alloys and additive manufacturing allow to produce components with reduced material and energy requirements. This reduction in weight boosts efficiency and lowers emissions, aligning with sustainability goals. However, working with lightweight alloys in AM can pose quality and safety challenges, requiring innovative testing techniques. The Stress Intensity Factor (SIF) threshold for crack growth and residual stresses (RS) are key parameters for the lightweight design of AM parts subjected to fatigue loads. Conventional methods are often lengthy and incompatible with fast-paced industrial environments. The FAAST project proposes an innovative testing procedure which combines RS measure and ultrasonic fatigue tests to explore the threshold region for crack growth with numerical models that estimate SIF values at the crack tip under ultrasonic fatigue loading conditions. This new approach significantly reduces the time needed to assess the SIF threshold, enabling manufacturers to maintain safety and reliability while accelerating the design and testing process. By adopting such advanced testing strategies, industries can uphold rigorous quality control without compromising the flexibility and efficiency that lightweight alloys AM offers.