An analysis of fatigue failure mechanisms in an additively manufactured and shot peened IN 718 nickel superalloy

The family of additive manufacturing techniques has been attracting significant attention of manufacturers and researchers, due to its unrivalled flexibility to fabricate and repair geometrically complex objects. However, material shaping is not sufficient: wide adoption of additive manufacturing can only occur upon the achievement of satisfactory mechanical performance in terms of structural integrity. The present study exploits a wide range of micro-scale experimental techniques to shed light on fatigue failure mechanisms of Laser Metal Deposition IN718 Ni-base superalloy, and to study the effect of shot peening treatment. Thorough microstructural and fractographic analyses revealed the main deformation mechanism associated with twinning during crack propagation, while crack initiation was found to be promoted by both slip system deformation and twinning around microstructural defects, rather than at sample free-surfaces. It was found that precipitates played a major role in determining the deformation mode. It was discovered that in this case-study, shot-peening residual stresses may have a detrimental effect, in view of the presence of the largest defects within a region where tensile residual stress was present. The results presented here improve understanding of failure mechanisms and thus define future directions of development for manufacture optimisation. [Display omitted] •Fatigue microstructural characteristics and presence of residual stress in additively manufactured IN718 were studied.•Fatigue cracks originated at the surface of large internal material defects (i.e. void).•Twinning deformation was found to be the dominant deformation mechanism during fatigue crack propagation · A high concentration of Chromium was found at the defect where crack nucleation occurred.•Shot peening was found to be detrimental in this instance due to the tensile residual stress in the bulk of the material