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Insights into Fatigue Damage in Additive Manufacturing through Process-Structure-Property Interactions.

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Title: Insights into Fatigue Damage in Additive Manufacturing through Process-Structure-Property Interactions.
Authors: Uddin, Zia1,2 (AUTHOR) uddin22@itu.edu.tr, Shaikh, Mohsin Munir3 (AUTHOR) mohsin_shaikh88@hotmail.com, Mehran, Muhammad Kashif4 (AUTHOR) kashifmehran29@gmail.com, Ullah, Tehseen5 (AUTHOR) tehseenullahntu@gmail.com, Shafique, Orva6 (AUTHOR) orva.shafique@studio.unibo.it, Hussnain, Muhammad7 (AUTHOR) muhammad.hussnain@um.edu.mt
Source: Journal of Failure Analysis & Prevention. Dec2025, Vol. 25 Issue 6, p2651-2686. 36p.
Subjects: Selective laser melting, Microstructure, Cohesion, Mechanical behavior of materials, Laser sintering, Fatigue cracks, Crack propagation
Abstract: Additive manufacturing (AM) has transformed modern production by enabling complex geometries, reducing material waste, and shortening lead times. Yet, a central challenge in metal AM remains ensuring structural integrity and long-term performance under cyclic and monotonic loads, given the process-induced defects and heterogeneous microstructures inherent to layer-wise fabrication. Among metal AM routes, selective laser melting (SLM), a powder bed fusion process, dominates high-performance applications and presents distinctive damage-tolerance challenges arising from rapid thermal cycling and defect sensitivity. This review critically examines how SLM process parameters govern defect formation, microstructure evolution, and the resulting fatigue and fracture responses under mechanical loading. Particular emphasis is placed on the interplay among processing conditions, melt-pool dynamics, microstructural gradients, and property anisotropy. The role of gradient structures in crack initiation and propagation is assessed, highlighting mechanisms that control small-crack growth and thresholds. By synthesizing current evidence and exposing gaps, especially in quantitative links from process parameters to damage tolerance, this review provides guidance for designing more reliable, durable metal components manufactured via SLM. [ABSTRACT FROM AUTHOR]
Copyright of Journal of Failure Analysis & Prevention is the property of Springer Nature and its content may not be copied or emailed to multiple sites without the copyright holder's express written permission. Additionally, content may not be used with any artificial intelligence tools or machine learning technologies. However, users may print, download, or email articles for individual use. This abstract may be abridged. No warranty is given about the accuracy of the copy. Users should refer to the original published version of the material for the full abstract. (Copyright applies to all Abstracts.)
Database: Engineering Source
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DbLabel: Engineering Source
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PubType: Academic Journal
PubTypeId: academicJournal
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  Data: Insights into Fatigue Damage in Additive Manufacturing through Process-Structure-Property Interactions.
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  Data: <searchLink fieldCode="AR" term="%22Uddin%2C+Zia%22">Uddin, Zia</searchLink><relatesTo>1,2</relatesTo> (AUTHOR)<i> uddin22@itu.edu.tr</i><br /><searchLink fieldCode="AR" term="%22Shaikh%2C+Mohsin+Munir%22">Shaikh, Mohsin Munir</searchLink><relatesTo>3</relatesTo> (AUTHOR)<i> mohsin_shaikh88@hotmail.com</i><br /><searchLink fieldCode="AR" term="%22Mehran%2C+Muhammad+Kashif%22">Mehran, Muhammad Kashif</searchLink><relatesTo>4</relatesTo> (AUTHOR)<i> kashifmehran29@gmail.com</i><br /><searchLink fieldCode="AR" term="%22Ullah%2C+Tehseen%22">Ullah, Tehseen</searchLink><relatesTo>5</relatesTo> (AUTHOR)<i> tehseenullahntu@gmail.com</i><br /><searchLink fieldCode="AR" term="%22Shafique%2C+Orva%22">Shafique, Orva</searchLink><relatesTo>6</relatesTo> (AUTHOR)<i> orva.shafique@studio.unibo.it</i><br /><searchLink fieldCode="AR" term="%22Hussnain%2C+Muhammad%22">Hussnain, Muhammad</searchLink><relatesTo>7</relatesTo> (AUTHOR)<i> muhammad.hussnain@um.edu.mt</i>
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  Data: <searchLink fieldCode="JN" term="%22Journal+of+Failure+Analysis+%26+Prevention%22">Journal of Failure Analysis & Prevention</searchLink>. Dec2025, Vol. 25 Issue 6, p2651-2686. 36p.
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  Data: <searchLink fieldCode="DE" term="%22Selective+laser+melting%22">Selective laser melting</searchLink><br /><searchLink fieldCode="DE" term="%22Microstructure%22">Microstructure</searchLink><br /><searchLink fieldCode="DE" term="%22Cohesion%22">Cohesion</searchLink><br /><searchLink fieldCode="DE" term="%22Mechanical+behavior+of+materials%22">Mechanical behavior of materials</searchLink><br /><searchLink fieldCode="DE" term="%22Laser+sintering%22">Laser sintering</searchLink><br /><searchLink fieldCode="DE" term="%22Fatigue+cracks%22">Fatigue cracks</searchLink><br /><searchLink fieldCode="DE" term="%22Crack+propagation%22">Crack propagation</searchLink>
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  Data: Additive manufacturing (AM) has transformed modern production by enabling complex geometries, reducing material waste, and shortening lead times. Yet, a central challenge in metal AM remains ensuring structural integrity and long-term performance under cyclic and monotonic loads, given the process-induced defects and heterogeneous microstructures inherent to layer-wise fabrication. Among metal AM routes, selective laser melting (SLM), a powder bed fusion process, dominates high-performance applications and presents distinctive damage-tolerance challenges arising from rapid thermal cycling and defect sensitivity. This review critically examines how SLM process parameters govern defect formation, microstructure evolution, and the resulting fatigue and fracture responses under mechanical loading. Particular emphasis is placed on the interplay among processing conditions, melt-pool dynamics, microstructural gradients, and property anisotropy. The role of gradient structures in crack initiation and propagation is assessed, highlighting mechanisms that control small-crack growth and thresholds. By synthesizing current evidence and exposing gaps, especially in quantitative links from process parameters to damage tolerance, this review provides guidance for designing more reliable, durable metal components manufactured via SLM. [ABSTRACT FROM AUTHOR]
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  Label:
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  Data: <i>Copyright of Journal of Failure Analysis & Prevention is the property of Springer Nature and its content may not be copied or emailed to multiple sites without the copyright holder's express written permission. Additionally, content may not be used with any artificial intelligence tools or machine learning technologies. However, users may print, download, or email articles for individual use. This abstract may be abridged. No warranty is given about the accuracy of the copy. Users should refer to the original published version of the material for the full abstract.</i> (Copyright applies to all Abstracts.)
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        Value: 10.1007/s11668-025-02305-5
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      – Code: eng
        Text: English
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      Pagination:
        PageCount: 36
        StartPage: 2651
    Subjects:
      – SubjectFull: Selective laser melting
        Type: general
      – SubjectFull: Microstructure
        Type: general
      – SubjectFull: Cohesion
        Type: general
      – SubjectFull: Mechanical behavior of materials
        Type: general
      – SubjectFull: Laser sintering
        Type: general
      – SubjectFull: Fatigue cracks
        Type: general
      – SubjectFull: Crack propagation
        Type: general
    Titles:
      – TitleFull: Insights into Fatigue Damage in Additive Manufacturing through Process-Structure-Property Interactions.
        Type: main
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            NameFull: Uddin, Zia
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            NameFull: Shaikh, Mohsin Munir
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            NameFull: Mehran, Muhammad Kashif
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            NameFull: Ullah, Tehseen
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            – D: 01
              M: 12
              Text: Dec2025
              Type: published
              Y: 2025
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