EA
E. Arnarsson
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Wire and Arc Additive Manufacturing (WAAM) enables large-scale steel fabrication but often produces rough surfaces that are detrimental under cyclic loading. This thesis investigates how surface finish affects the fatigue performance of WAAM AM70, a high-strength steel comparable to S690, through strain-controlled low-cycle fatigue (LCF) and stress-controlled high-cycle fatigue (HCF) tests. As-built and machined specimens were compared, revealing surface finish as the dominant fatigue driver. Machining increased fatigue strength by factors of 3–9 and reduced scatter. The study provides EN 1990:2023-compliant design curves and mechanistic insight, showing that machined WAAM AM70 achieves fatigue performance approaching conventional S690.
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Wire and Arc Additive Manufacturing (WAAM) enables large-scale steel fabrication but often produces rough surfaces that are detrimental under cyclic loading. This thesis investigates how surface finish affects the fatigue performance of WAAM AM70, a high-strength steel comparable to S690, through strain-controlled low-cycle fatigue (LCF) and stress-controlled high-cycle fatigue (HCF) tests. As-built and machined specimens were compared, revealing surface finish as the dominant fatigue driver. Machining increased fatigue strength by factors of 3–9 and reduced scatter. The study provides EN 1990:2023-compliant design curves and mechanistic insight, showing that machined WAAM AM70 achieves fatigue performance approaching conventional S690.