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Streszczenie:
Present investigation systematically quantifies the role of interior defect morphology on tensile fracture behavior in Binder Jetting Additive Manufactured (BJAM) 17-4 PH stainless steel. Unlike prior investigations relying on stochastic natural defects, BJAM is uniquely employed to fabricate tensile specimens with five precisely controlled interior defect geometries such as spherical, disc-shaped, ellipsoidal, inclined ellipsoidal, and two-spherical at the mid-gauge location of round and square cross-sectional configurations. These artificial defects, occupying 16–35% of the gross cross-sectional area, serve as morphologically defined analogues of shrinkage porosities typical of conventional steel castings. A novel shape-independent empirical net section yielding method is developed that directly correlates projected defect area to fracture stress across all five defect geometries and both cross-sectional configurations. Results demonstrate that tensile strength reduction is governed by projected defect area independent of defect shape, with predictions falling within ±10% for the majority of configurations, providing a practically applicable fracture stress prediction tool for defect containing BJAM components. 3D finite element simulations coupled with a ductile damage model are implemented to accurately predict crack initiation sites and experimental load–displacement responses, achieving excellent agreement with experimental findings and providing independent computational validation of the empirical framework.

Słowa kluczowe:
Binder jetting additive manufacturing, Ductile damage model, Interior defects, Shrinkage porosity, 17-4PH steel

Streszczenie:
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.

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