Effects of residual stress on orientation dependent fatigue crack growth rates in additively manufactured stainless steel

•The online crack compliance method was used for the first time on AM materials.•Consistent residual stress intensity factors (Kres) were found for each orientation.•DED material exhibited higher FCGRs when compared to wrought specimens.•Correcting for Kres brings FCGRs of DED and wrought material into agreement.•There is no significant orientation dependence of crack path in the AM material. Localized heating and resulting temperature gradients during additive manufacturing (AM) create significant residual stress that influences mechanical behavior, such as fatigue performance. To quantify residual stress effects on fatigue crack growth in AM materials, crack growth rates parallel and perpendicular to the build direction in directed energy deposition (DED) Type 304L austenitic stainless steel were measured. The on-line crack compliance method was used to determine the residual stress intensity factor, Kres, while simultaneously collecting fatigue crack growth rate (FCGR) data. Constant applied alternating stress intensity factor (constant ΔKapp) tests revealed the primary influence on measured FCGR is the orientation dependent Kres. Critical analysis of the compliance data from decreasing ΔKapp tests was used to quantify Kres, which was then used to correct FCGR data in the near-threshold regime. Results demonstrated that the fatigue response of DED Type 304L is inherently similar to that of annealed wrought Type 304/304L.