The introduction of Additive Manufacturing (AM) is changing the way in which components and machines can be designed and manufactured. Within this context, designers are taking advantage of the possibilities of producing parts via the addition of material, defining strategies, and exploring alternative design or optimization solutions (i.e., nonviable using subtractive technologies) of critical parts (e.g., gears and shafts). However, a safe and effective design requires specific resistance data that, due to the intrinsic modernity of additive technologies, are not always present in the literature. This paper presents the results of an experimental campaign performed on gear-samples made by 17-4 PH and produced via Laser Powder Bed Fusion (PBF-LB/M). The tests were executed using the Single Tooth Bending Fatigue (STBF) approach on a mechanical pulsator. The fatigue limit was determined using two different statistical approaches according to Dixon and Little. The obtained data were compared to those reported in the ISO standard for steels of similar performance. Additional analyses, i.e., Scanning Electron Microscopy SEM, were carried out to provide a further insight of the behavior 17-4PH AM material and in order to investigate the presence of possible defects in the tested gears, responsible for the final failure.
Design approaches for printability-performance synergy in Al alloys for laser-powder bed additive manufacturing
