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Additive layer manufacturing (ALM) processes are becoming increasingly prevalent in the aerospace industry as design engineers look to profit from the numerous advantages that these advanced techniques can offer. However, given the safety critical nature and arduous operating conditions to which these components will be exposed to whilst in service, it is essential that the mechanical properties of such structures are fully understood. Transient microstructures are a typical characteristic of ALM components and resulting from the thermal cycles that occur during the build operation. Those microstructures make any mechanical assessment an involved procedure when assessing the process variables for any given parameter set. A useful mechanical test technique is small-scale testing, in particular, the small punch (SP) test. SP testing is capable of localised sampling of a larger scale component and presents an attractive option to mechanically assess complex parts with representative geometries, that would not be possible using more conventional uniaxial test approaches. This paper will present the recent development of a small-scale testing methodology capable of inducing fatigue damage and a series of novel tests performed on different variants of Ti-6Al-4V.

Application of the small punch test to determine the fatigue properties of additive manufactured aerospace alloys