Investigation Into the Fatigue Life and Behavior of WAAM AM70 Steel

Master Thesis (2025)
Author(s)

E. Arnarsson (TU Delft - Civil Engineering & Geosciences)

Contributor(s)

T. Tankova – Mentor (TU Delft - Civil Engineering & Geosciences)

H. El Bamby – Mentor (TU Delft - Civil Engineering & Geosciences)

V. Popovich – Graduation committee member

M.J.M.M. Steenbergen – Graduation committee member

Faculty
Civil Engineering & Geosciences
More Info
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Publication Year
2025
Language
English
Graduation Date
30-10-2025
Awarding Institution
Delft University of Technology
Project
IAMFat Project
Programme
Civil Engineering, Structural Engineering
Faculty
Civil Engineering & Geosciences
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Abstract

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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