About this Dataset

Effects Of As-built Surface With Varying Number Of Contour Passes On High-cycle Fatigue Behavior Of Additively Manufactured Nickel Alloy 718

Abstract (from the manuscript): High cycle fatigue life of laser-powder bed fusion (L-PBF) parts depends on several factors; as-built surfaces, when present, are a particular concern. This work measures as-built L-PBF surfaces with X-ray computed tomography, and uses rotating beam fatigue (RBF) testing to measure high cycle fatigue life. Surfaces with different, but consistent, characteristics are achieved by build in vertical specimens and changing only the number of contour passes. In this way, specimens with three different levels of surface roughness are compared to standard polished specimens. The results from this show that surface roughness increases with decreasing number of contour passes, but the impact on fatigue lifetime is not trivially related. Electron microscopy and x-ray computed tomography images show multiple initiation points and complex surface topology, but that surface feature depth is not necessarily correlated to failure location. Two primary conclusions are that 1) for the case of as-built surfaces loaded in bending, one contour pass is sufficient to achieve peak as-built performance, and even zero contour passes was not statistically significantly different from two passes; 2) surface feature depth, even when measured using metal-penetrating imaging, is not strongly associated with failure location in our data. When assessing AM surfaces, more factors (e.g., grain orientation) may be required to mechanistically understand the performance implications.This dataset is comprised of four main types of data: 1. Build data, including CAD files and heat treatment logs. 2. Fatigue data, from RBF testing tabulated in the form of measured stresses and forces, and fatigue lives (cycle counts). 3. Fractography data, in the form of SEM and optical images of failure surfaces after RBF testings. 4. X-ray Computed Tomography data, comprising 3D images, associated image processing codes, and tabulated data describing the surface profiles and deepest surface notches for 6 specimens of particular interest.
Organization: Department of Commerce
Last updated: 2025-09-30T05:23:12.558274
Tags: additive-manufacturing, as-built, laser-powder-bed-fusion, nickel-alloy-718, rotating-beam-fatigue, surface-roughness

Tables

Fatigue Data/fatigue Stats/confidence Bands

@usgov.doc_gov_effects_of_as_built_surface_with_varying_numbe_34a4bbde.fatigue_data_fatigue_stats_confidence_bands

57.73 kB
2,000 rows
5 columns

CREATE TABLE fatigue_data_fatigue_stats_confidence_bands (
  "unnamed_0" BIGINT  -- Unnamed: 0,
  "type" VARCHAR,
  "s" DOUBLE,
  "lower" DOUBLE,
  "upper" DOUBLE
);

Fatigue Data/fatigue Stats/SN Curve Fits

@usgov.doc_gov_effects_of_as_built_surface_with_varying_numbe_34a4bbde.fatigue_data_fatigue_stats_sn_curve_fits

38.37 kB
2,000 rows
4 columns

CREATE TABLE fatigue_data_fatigue_stats_sn_curve_fits (
  "unnamed_0" BIGINT  -- Unnamed: 0,
  "s_fit" DOUBLE,
  "n_log10" DOUBLE,
  "type" VARCHAR
);

Fatigue Data/RBF Results 30um

@usgov.doc_gov_effects_of_as_built_surface_with_varying_numbe_34a4bbde.fatigue_data_rbf_results_30um

19.12 kB
70 rows
21 columns

CREATE TABLE fatigue_data_rbf_results_30um (
  "layer_height" BIGINT,
  "number" DOUBLE,
  "type" VARCHAR,
  "diameter_mm_caliper_4_04_nominal_top" DOUBLE  -- Diameter [mm] (caliper) (4.04 Nominal) [top],
  "diameter_mm_caliper_4_04_nominal_middle" DOUBLE  -- Diameter [mm] (caliper) (4.04 Nominal) [middle],
  "diameter_mm_caliper_4_04_nominal_bottom" DOUBLE  -- Diameter [mm] (caliper) (4.04 Nominal) [bottom],
  "stress_level_mpa" VARCHAR  -- Stress Level [MPa],
  "force_to_be_applied_n" VARCHAR  -- Force To Be Applied [N],
  "cycles_to_failure" DOUBLE,
  "actual_force" DOUBLE,
  "notes" VARCHAR,
  "initial_variability_check" VARCHAR,
  "force_variability_from_test_log" DOUBLE,
  "stress_variability" DOUBLE,
  "unnamed_14" VARCHAR  -- Unnamed: 14,
  "unnamed_15" VARCHAR  -- Unnamed: 15,
  "unnamed_16" VARCHAR  -- Unnamed: 16,
  "unnamed_17" VARCHAR  -- Unnamed: 17,
  "unnamed_18" VARCHAR  -- Unnamed: 18,
  "unnamed_19" VARCHAR  -- Unnamed: 19,
  "unnamed_20" VARCHAR  -- Unnamed: 20
);

Table 1

@usgov.doc_gov_effects_of_as_built_surface_with_varying_numbe_34a4bbde.table_1

19.12 kB
70 rows
21 columns

CREATE TABLE table_1 (
  "layer_height" BIGINT,
  "number" DOUBLE,
  "type" VARCHAR,
  "diameter_mm_caliper_4_04_nominal_top" DOUBLE  -- Diameter [mm] (caliper) (4.04 Nominal) [top],
  "diameter_mm_caliper_4_04_nominal_middle" DOUBLE  -- Diameter [mm] (caliper) (4.04 Nominal) [middle],
  "diameter_mm_caliper_4_04_nominal_bottom" DOUBLE  -- Diameter [mm] (caliper) (4.04 Nominal) [bottom],
  "stress_level_mpa" VARCHAR  -- Stress Level [MPa],
  "force_to_be_applied_n" VARCHAR  -- Force To Be Applied [N],
  "cycles_to_failure" DOUBLE,
  "actual_force" DOUBLE,
  "notes" VARCHAR,
  "initial_variability_check" VARCHAR,
  "force_variability_from_test_log" DOUBLE,
  "stress_variability" DOUBLE,
  "unnamed_14" VARCHAR  -- Unnamed: 14,
  "unnamed_15" VARCHAR  -- Unnamed: 15,
  "unnamed_16" VARCHAR  -- Unnamed: 16,
  "unnamed_17" VARCHAR  -- Unnamed: 17,
  "unnamed_18" VARCHAR  -- Unnamed: 18,
  "unnamed_19" VARCHAR  -- Unnamed: 19,
  "unnamed_20" VARCHAR  -- Unnamed: 20
);

Xray Ct Data/analysis Data Files/1p1–30um Surf Roughness

@usgov.doc_gov_effects_of_as_built_surface_with_varying_numbe_34a4bbde.xray_ct_data_analysis_data_files_1p1_30um_surf_roughness

145.48 MB
11,116,666 rows
7 columns

CREATE TABLE xray_ct_data_analysis_data_files_1p1_30um_surf_roughness (
  "image_index" DOUBLE,
  "theta_angle_deg" DOUBLE  -- Theta Angle (deg),
  "centroid_row_index" DOUBLE,
  "centroid_column_index" DOUBLE,
  "surface_row_index" DOUBLE,
  "surface_column_index" DOUBLE,
  "radial_length_to_surface_um" DOUBLE  -- Radial Length To Surface (um)
);

Xray Ct Data/analysis Data Files/1p1–30um Sv3d

@usgov.doc_gov_effects_of_as_built_surface_with_varying_numbe_34a4bbde.xray_ct_data_analysis_data_files_1p1_30um_sv3d

62.22 kB
4,001 rows
2 columns

CREATE TABLE xray_ct_data_analysis_data_files_1p1_30um_sv3d (
  "image_index" BIGINT,
  "s_v_3d" DOUBLE
);

Xray Ct Data/analysis Data Files/1p2–30um Surf Roughness

@usgov.doc_gov_effects_of_as_built_surface_with_varying_numbe_34a4bbde.xray_ct_data_analysis_data_files_1p2_30um_surf_roughness

118.52 MB
9,088,373 rows
7 columns

CREATE TABLE xray_ct_data_analysis_data_files_1p2_30um_surf_roughness (
  "image_index" DOUBLE,
  "theta_angle_deg" DOUBLE  -- Theta Angle (deg),
  "centroid_row_index" DOUBLE,
  "centroid_column_index" DOUBLE,
  "surface_row_index" DOUBLE,
  "surface_column_index" DOUBLE,
  "radial_length_to_surface_um" DOUBLE  -- Radial Length To Surface (um)
);

Xray Ct Data/analysis Data Files/1p2–30um Sv3d

@usgov.doc_gov_effects_of_as_built_surface_with_varying_numbe_34a4bbde.xray_ct_data_analysis_data_files_1p2_30um_sv3d

51.55 kB
3,280 rows
2 columns

CREATE TABLE xray_ct_data_analysis_data_files_1p2_30um_sv3d (
  "image_index" BIGINT,
  "s_v_3d" DOUBLE
);

Xray Ct Data/analysis Data Files/1p3–30um Surf Roughness

@usgov.doc_gov_effects_of_as_built_surface_with_varying_numbe_34a4bbde.xray_ct_data_analysis_data_files_1p3_30um_surf_roughness

150.95 MB
11,040,972 rows
7 columns

CREATE TABLE xray_ct_data_analysis_data_files_1p3_30um_surf_roughness (
  "image_index" DOUBLE,
  "theta_angle_deg" DOUBLE  -- Theta Angle (deg),
  "centroid_row_index" DOUBLE,
  "centroid_column_index" DOUBLE,
  "surface_row_index" DOUBLE,
  "surface_column_index" DOUBLE,
  "radial_length_to_surface_um" DOUBLE  -- Radial Length To Surface (um)
);

Xray Ct Data/analysis Data Files/1p3–30um Sv3d

@usgov.doc_gov_effects_of_as_built_surface_with_varying_numbe_34a4bbde.xray_ct_data_analysis_data_files_1p3_30um_sv3d

64.42 kB
4,100 rows
2 columns

CREATE TABLE xray_ct_data_analysis_data_files_1p3_30um_sv3d (
  "image_index" BIGINT,
  "s_v_3d" DOUBLE
);

Xray Ct Data/analysis Data Files/21p1–30um Surf Roughness

@usgov.doc_gov_effects_of_as_built_surface_with_varying_numbe_34a4bbde.xray_ct_data_analysis_data_files_21p1_30um_surf_roughness

177.11 MB
13,725,952 rows
7 columns

CREATE TABLE xray_ct_data_analysis_data_files_21p1_30um_surf_roughness (
  "image_index" DOUBLE,
  "theta_angle_deg" DOUBLE  -- Theta Angle (deg),
  "centroid_row_index" DOUBLE,
  "centroid_column_index" DOUBLE,
  "surface_row_index" DOUBLE,
  "surface_column_index" DOUBLE,
  "radial_length_to_surface_um" DOUBLE  -- Radial Length To Surface (um)
);

Xray Ct Data/analysis Data Files/21p1–30um Sv3d

@usgov.doc_gov_effects_of_as_built_surface_with_varying_numbe_34a4bbde.xray_ct_data_analysis_data_files_21p1_30um_sv3d

77.41 kB
4,941 rows
2 columns

CREATE TABLE xray_ct_data_analysis_data_files_21p1_30um_sv3d (
  "image_index" BIGINT,
  "s_v_3d" DOUBLE
);

Xray Ct Data/analysis Data Files/21p2–30um Surf Roughness

@usgov.doc_gov_effects_of_as_built_surface_with_varying_numbe_34a4bbde.xray_ct_data_analysis_data_files_21p2_30um_surf_roughness

178.04 MB
13,765,541 rows
7 columns

CREATE TABLE xray_ct_data_analysis_data_files_21p2_30um_surf_roughness (
  "image_index" DOUBLE,
  "theta_angle_deg" DOUBLE  -- Theta Angle (deg),
  "centroid_row_index" DOUBLE,
  "centroid_column_index" DOUBLE,
  "surface_row_index" DOUBLE,
  "surface_column_index" DOUBLE,
  "radial_length_to_surface_um" DOUBLE  -- Radial Length To Surface (um)
);

Xray Ct Data/analysis Data Files/21p2–30um Sv3d

@usgov.doc_gov_effects_of_as_built_surface_with_varying_numbe_34a4bbde.xray_ct_data_analysis_data_files_21p2_30um_sv3d

77.52 kB
4,941 rows
2 columns

CREATE TABLE xray_ct_data_analysis_data_files_21p2_30um_sv3d (
  "image_index" BIGINT,
  "s_v_3d" DOUBLE
);

Xray Ct Data/analysis Data Files/21p3–30um Surf Roughness

@usgov.doc_gov_effects_of_as_built_surface_with_varying_numbe_34a4bbde.xray_ct_data_analysis_data_files_21p3_30um_surf_roughness

208.79 MB
15,202,516 rows
7 columns

CREATE TABLE xray_ct_data_analysis_data_files_21p3_30um_surf_roughness (
  "image_index" DOUBLE,
  "theta_angle_deg" DOUBLE  -- Theta Angle (deg),
  "centroid_row_index" DOUBLE,
  "centroid_column_index" DOUBLE,
  "surface_row_index" DOUBLE,
  "surface_column_index" DOUBLE,
  "radial_length_to_surface_um" DOUBLE  -- Radial Length To Surface (um)
);

Xray Ct Data/analysis Data Files/21p3–30um Sv3d

@usgov.doc_gov_effects_of_as_built_surface_with_varying_numbe_34a4bbde.xray_ct_data_analysis_data_files_21p3_30um_sv3d

88.05 kB
5,615 rows
2 columns

CREATE TABLE xray_ct_data_analysis_data_files_21p3_30um_sv3d (
  "image_index" BIGINT,
  "s_v_3d" DOUBLE
);