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Additive manufacturing (AM) provides exceptional geometrical freedom to the architects and designers and enables the construction of architecturally exposed steel structures. However, the AM structural elements inherently possess microscale defects that can affect their ductility. This study aims to identify the fracture-initiating mechanism in AM 17-4 stainless steel that is popularly used owing to its excellent engineering properties. To this end, axisymmetric cylindrical notched and unnotched tension specimens are manufactured employing direct metal laser sintering from 17-4 stainless steel powder with established processing and build parameters. The test specimens were manufactured using a 90° build orientation with the build plate and a layer thickness of 40 μm. Postprocessing heat treatment was avoided as the study focused on understanding the failure mechanism in as-built AM test specimens. Detailed metallurgical analysis is performed employing scanning electron microscopy (SEM) and electron backscatter diffraction. Subsequently, micro–computed tomography (CT) studies are conducted on the tension specimens before and after mechanical testing. Although the SEM analyses of fracture surfaces are inconclusive, the micro-CT analysis revealed evidence of nucleation of new microvoids, growth of existing voids, and void coalescence in the vicinity of the fracture surface, which is unequivocal evidence for ductile fracture. Furthermore, the larger AM defects were found to play an important role in lowering the ductility in addition to stress concentration, and the fracture was initiated when the AM defects coalesced over a length of around 600 μm. The conclusions of this study emphasize the importance of controlling the maximum size of defects in AM structural elements to improve their performance. [ABSTRACT FROM AUTHOR]

In this paper a selection of modern, commercial steels for automotive and pipeline applications, in different grades, microstructures and delivery conditions has been characterized, quantifying the void distribution on virgin materials and on several deformed and fractured specimens, including tensile tests at different triaxiality and torsion tests. The results described in the paper show that in such class of material the measured void fraction is fully negligible and not related to the plastic strain applied, even at the fracture proximity. The consequence is that also the matrix softening hypothesis may be dropped in the plastic behavior and that damage due to void evolution hypothesis is not adequate. [ABSTRACT FROM AUTHOR]

Modern high strength and ductile steels are a key element of US Navy ship structural technology. The development of these alloys spurred the development of modern structural integrity analysis methods over the past 70 years. Strength and ductility provided the designers and builders of navy surface ships and submarines with the opportunity to reduce ship structural weight, increase hull stiffness, increase damage resistance, improve construction practices and reduce maintenance costs. This paper reviews how analytical and computational tools, driving simulation methods and experimental techniques, were developed to provide ongoing insights into the material, damage and fracture characteristics of these alloys. The need to understand alloy fracture mechanics provided unique motivations to measure and model performance from structural to microstructural scales. This was done while accounting for the highly nonlinear behaviours of both materials and underlying fracture processes. Theoretical methods, data acquisition strategies, computational simulation and scientific imaging were applied to increasingly smaller scales and complex materials phenomena under deformation. Knowledge gained about fracture resistance was used to meet minimum fracture initiation, crack growth and crack arrest characteristics as part of overall structural integrity considerations. [ABSTRACT FROM AUTHOR]