Abstract
This study introduces a microstructure-sensitive fatigue life prediction framework based on CP-FFT which includes the effect of surface roughness. The model is applied to flat Hastelloy-X specimens fabricated using Selective Laser Melting. The surface roughness measured is incorporated introducing a free surface with sinusoidal profile. The framework can accurately predict the fatigue life reduction of rough flat specimens using the fatigue parameters of polished bulk specimens and introducing the actual microstructure and roughness. A parametric study shows a monotonic reduction of life with the roughness amplitude but a minor effect of the surface waviness.
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