This analysis uncovers the size effect on high-cycle fatigue in Ti-6Al-4V samples, suggesting improved design for enhanced durability.
As AM engineering components often possess complex structures and varying cross‐sectional dimensions, they frequently exhibit unstable service performance due to the print dimension size effect. This variability in performance is one of the most typical problems in AM components. This study investigates the size effect on the high‐cycle fatigue performance of the widely used AM alloy, Ti‐6Al‐4V. The influence of sample size on fatigue performance is explored through fatigue source analysis, fatigue life analysis, and defect statistics. A new statistical model is proposed to predict the theoretical largest defect in samples with small dimensions, based on observations of relatively large regions. This model is particularly suitable for the commonly thin‐walled AM components. The corresponding fatigue life prediction is then achieved by integrating the microstructure void coupling (MVC) model.
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Zhang et al. (2025) studied this question.
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