Modelling of the surface morphology and size effects on fatigue strength of L-PBF Inconel 718 by comparing different testing specimens

The aim of this study was to investigate the impact of surface roughness and size effect on the uniaxial fatigue strength of aged specimens made of Inconel 718, obtained by laser-powder bed fusion (L-PBF) both under as-built and machined surface conditions. The surface profiles were scanned with a 3D optical profilometer, and then modelled and filtered by the fast Fourier transform. This latter allowed to obtain the relevant parameters to calculate the term area in the Murakami model to account for the effect of surface roughness on fatigue strength prediction. Two additional terms were added to the standard Murakami formula: one to account for the size effect and the other to consider the nonzero value of the average stress. A cylindrical plain and a miniaturized plain specimens, in the as-built condition, were employed to calibrate the proposed model, while a machined plain cylindrical and a miniaturized notched specimens were used as validators with low prediction errors.