Fatigue Life of Additive Manufactured Aluminum

Thanks for the comments & questions regarding Additive Manufacturing (AM) and material properties. Our motto, see below, really is our mission statement. We learn when you send us problems.

Today we post a video reporting on material properties of AM build aluminum parts. To maximize the material properties of aluminum requires alloying and heat treatment. Typical aluminum welding wires are either silicon alloy 4000 series or magnesium alloy 5000 series, neither of which is heat treatable. Brian Harrison with Alcotec Wire Co graciously supplied a spool of heat treatable copper alloyed 2319 wire. After solution heat treat and aging, we measured tensile strength at 63,000 psi. This means you can use AM to build an aluminum part with the strength of steel and 1/3 the weight.

Next, we built a 5356 aluminum test specimen using AM for fully reversed cyclical fatigue testing at 70% of the tensile strength (130% of yield). The part survived 5,500 cycles. Less than a heat-treated 6061-T6 part but not bad. This is useful data as we build our reference library of AM material properties.

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