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Abstract:
This study advances beyond qualitative strength reduction trends in additive manufacturing fracture studies by establishing quantitative, configuration-based fracture assessment for Binder Jetting Additive Manufactured (BJ-AM) 17–4PH stainless steel with engineered surface cracks. Multiple crack geometries such as edge, inclined, single-corner, and double-corner configurations were precisely implanted in square (7 × 7 mm) and rectangular (3.5 × 14 mm) specimens with identical cross-sectional areas. Experimental investigations demonstrate that fracture resistance is governed by crack configuration and geometry-induced constraint, not crack area alone. Double-corner cracks retained 79–86% strength despite 25% crack area, while single-edge cracks exhibited 46–54% retention with only 20% crack area. Thickness-dependent constraint effects unique to BJ-AM geometries were quantified through comparative testing, revealing rectangular specimens (3.5 mm thickness) exhibit reduced constraint and lower fracture resistance than square specimens (7 mm thickness). J-integral governed elastic-plastic fracture assessment, validated through Extended Finite Element Method simulations predicting failure within ±10%, establishing predictive frameworks for defect-tolerant BJ-AM structural design.

Keywords:
Binder jetting additive manufacturing, Fracture toughness, J-integral, Extended finite element method, Surface cracks, 17–4PH stainless steel