Design based on an existing component geometry as a part of a structure was conducted. The design was manufactured using the laser powder bed fusion (L-PBF) technique. The reliability and consistent quality of AM materials are important aspects of the critical components manufacturing and verification process. Consequently, the same design was built with two different L-PBF setups for experimental studies. The effect of shop peening was studied as a potential fatigue performance improvement method. Experimental fatigue testing for the AM titanium component was conducted. The experimental study also includes surface quality and metallurgical analysis. Fatigue testing was supplemented with SEM fractography. The AM part exceeded design requirements for maximum service load significantly. The results highlight the potential of AM for component manufacturing in both new designs and replacing conventionally manufactured parts.

Directed energy deposition with electric arc (DED-arc) can be used to manufacture components with high deposition rate. Furthermore, the productivity can be increased by utilizing DED material and components together with conventional plates and profiles. In this study, DED-arc parts and components made of aluminum material are studied. First, experimental fatigue tests are conducted for DED coupons. The material testing is followed by joining DED-produced coupon to plate with gas metal arc welding (GMAW) as butt joint configuration. The butt-welded joints are subjected to fatigue loading and the results are compared to plain DED material. The final part of the experimental testing widens the scope of the study to component level. The component-like specimen is manufactured in two possible manners. Oval shape thin-walled DED part is connected to a base plate that is loaded. The first case is to deposit the DED oval feature directly on top of the plate. The second case is to use platter to manufacture several DED oval features and then connect the DED part to the plate by fillet weld. In both cases, the global geometry is kept similar, whereas the residual stress state varies. Fatigue test results of the DED material, butt weld joint and component-like specimens are then discussed considering local properties.