Investigating Fracture of Ti-6Al-4V Tensile Specimens Manufactured by Electron Beam Powder Bed Fusion Using XFEM

Investigating Fracture of Ti-6Al-4V Tensile Specimens Manufactured by Electron Beam Powder Bed Fusion Using XFEM | Research Square window.SnipcartSettings = { analytics: { enabled: false } }; (function() { var accessVector = localStorage.getItem('access_vector') || ''; window.dataLayer = window.dataLayer || []; if (accessVector) { window.dataLayer.push({ user: { profile: { profileInfo: { snid: accessVector } } } }); } })(); (function(w,d,s,l,i){w[l]=w[l]||[];w[l].push({'gtm.start':new Date().getTime(),event:'gtm.js'});var f=d.getElementsByTagName(s)[0],j=d.createElement(s),dl=l!='dataLayer'?'&l='+l:'';j.async=true;j.src='https://www.googletagmanager.com/gtm.js?id='+i+dl;f.parentNode.insertBefore(j,f);})(window,document,'script','dataLayer','GTM-K279D39R'); Browse Preprints In Review Journals COVID-19 Preprints AJE Video Bytes Research Tools Research Promotion AJE Professional Editing AJE Rubriq About Preprint Platform In Review Editorial Policies Our Team Advisory Board Help Center Sign In Submit a Preprint Cite Share Download PDF Research Article Investigating Fracture of Ti-6Al-4V Tensile Specimens Manufactured by Electron Beam Powder Bed Fusion Using XFEM Bahman Paygozar This is a preprint; it has not been peer reviewed by a journal. https://doi.org/ 10.21203/rs.3.rs-9396217/v1 This work is licensed under a CC BY 4.0 License Status: Posted Version 1 posted You are reading this latest preprint version Abstract This study aims to reliably predict the fracture load of the rectangular Ti-6Al-4V dogbone specimen fabricated by electron beam powder bed fusion (EB-PBF). Tensile tests were conducted, and corresponding numerical simulations were performed. The experimental data obtained from standard tensile tests were used to extract the mechanical properties of the material. Subsequently, the load-displacement responses from the experiments were used to calibrate the fracture properties for use in failure analyses performed using the extended finite element method (XFEM) by comparing the corresponding numerical and experimental results. This calibration process ensured that the model realistically represents damage initiation and evolution. It was also shown that the XFEM approach successfully captures crack initiation and propagation. The data (e.g., stiffness and fracture load) obtained from experimental tensile tests were compared with the results of numerical analyses. The discrepancy between the numerical and experimental results was within an acceptable range (below 5%) for the dogbone specimen. These findings highlighted the potential of XFEM as a reliable tool for predicting the fracture behavior of EB-PBF-produced specimens under tensile loading. Electron beam powder bed fusion Dogbone specimen Extended finite element method Fracture load Full Text Additional Declarations No competing interests reported. Cite Share Download PDF Status: Posted Version 1 posted You are reading this latest preprint version Research Square lets you share your work early, gain feedback from the community, and start making changes to your manuscript prior to peer review in a journal. As a division of Research Square Company, we’re committed to making research communication faster, fairer, and more useful. We do this by developing innovative software and high quality services for the global research community. Our growing team is made up of researchers and industry professionals working together to solve the most critical problems facing scientific publishing. Also discoverable on Platform About Our Team In Review Editorial Policies Advisory Board Help Center Resources Author Services Accessibility API Access RSS feed Manage Cookie Preferences © Research Square 2026 | ISSN 2693-5015 (online) Privacy Policy Terms of Service Do Not Sell My Personal Information {"props":{"pageProps":{"initialData":{"identity":"rs-9396217","acceptedTermsAndConditions":true,"allowDirectSubmit":true,"archivedVersions":[],"articleType":"Research Article","associatedPublications":[],"authors":[{"id":621770358,"identity":"d9c59c67-1df2-4eb6-82ed-0f5ac4d8e2b0","order_by":0,"name":"Bahman Paygozar","email":"data:image/png;base64,iVBORw0KGgoAAAANSUhEUgAAAZAAAAAyAQMAAABI0h/eAAAABlBMVEX///8AAABVwtN+AAAACXBIWXMAAA7EAAAOxAGVKw4bAAAA4klEQVRIiWNgGAWjYBACAziLvQFMMTYQr4XnAFg1kGAmVotEApFazKWbn0l+qaiTN5/5+PhjHgYb2Q0H+I99wKfFcs4xM2mZM2yGc26nJTbzMKQZbzjAzDwDr8NuJJhJS7bxMM6QzjEEajmcCNKC3y830r8BtUjYz5A8/xGo5T8xWnLMJD+2GSTOkOBhBGo5QFiL5ZwzxdYMZxKSZ/CkGc6cY5BsPPMwszFeLebS7Rtv/qios53BfvjBhzcVdrJ9xxsf49XCIMHAIs2DcCcQE4gWkBbmjz8IKRoFo2AUjIKRDQAD3kdqxPbQsgAAAABJRU5ErkJggg==","orcid":"","institution":"TOBB University of Economics and Technology","correspondingAuthor":true,"prefix":"","firstName":"Bahman","middleName":"","lastName":"Paygozar","suffix":""}],"badges":[],"createdAt":"2026-04-12 18:29:41","currentVersionCode":1,"declarations":"","doi":"10.21203/rs.3.rs-9396217/v1","doiUrl":"https://doi.org/10.21203/rs.3.rs-9396217/v1","draftVersion":[],"editorialEvents":[],"editorialNote":"","failedWorkflow":false,"files":[{"id":106961196,"identity":"f425f195-a8da-426c-ab61-ca45f977334e","added_by":"auto","created_at":"2026-04-15 09:24:41","extension":"pdf","order_by":1,"title":"","display":"","copyAsset":false,"role":"manuscript-pdf","size":683865,"visible":true,"origin":"","legend":"","description":"","filename":"1.ManuEBPBFV3Anonymised.pdf","url":"https://assets-eu.researchsquare.com/files/rs-9396217/v1_covered_61a97dee-57cd-473d-9449-9d67ce70f6e7.pdf"}],"financialInterests":"No competing interests reported.","formattedTitle":"Investigating Fracture of Ti-6Al-4V Tensile Specimens Manufactured by Electron Beam Powder Bed Fusion Using XFEM","fulltext":[],"fulltextSource":"","fullText":"","funders":[],"hasAdminPriorityOnWorkflow":false,"hasManuscriptDocX":false,"hasOptedInToPreprint":true,"hasPassedJournalQc":"","hasAnyPriority":true,"hideJournal":true,"highlight":"","institution":"","isAcceptedByJournal":false,"isAuthorSuppliedPdf":true,"isDeskRejected":"","isHiddenFromSearch":false,"isInQc":false,"isInWorkflow":false,"isPdf":true,"isPdfUpToDate":true,"isWithdrawnOrRetracted":false,"journal":{"display":true,"email":"[email protected]","identity":"researchsquare","isNatureJournal":false,"hasQc":true,"allowDirectSubmit":true,"externalIdentity":"","sideBox":"","snPcode":"","submissionUrl":"/submission","title":"Research Square","twitterHandle":"researchsquare","acdcEnabled":true,"dfaEnabled":false,"editorialSystem":"","reportingPortfolio":"","inReviewEnabled":false,"inReviewRevisionsEnabled":true},"keywords":"Electron beam powder bed fusion, Dogbone specimen, Extended finite element method, Fracture load","lastPublishedDoi":"10.21203/rs.3.rs-9396217/v1","lastPublishedDoiUrl":"https://doi.org/10.21203/rs.3.rs-9396217/v1","license":{"name":"CC BY 4.0","url":"https://creativecommons.org/licenses/by/4.0/"},"manuscriptAbstract":"This study aims to reliably predict the fracture load of the rectangular Ti-6Al-4V dogbone specimen fabricated by electron beam powder bed fusion (EB-PBF). Tensile tests were conducted, and corresponding numerical simulations were performed. The experimental data obtained from standard tensile tests were used to extract the mechanical properties of the material. Subsequently, the load-displacement responses from the experiments were used to calibrate the fracture properties for use in failure analyses performed using the extended finite element method (XFEM) by comparing the corresponding numerical and experimental results. This calibration process ensured that the model realistically represents damage initiation and evolution. It was also shown that the XFEM approach successfully captures crack initiation and propagation. The data (e.g., stiffness and fracture load) obtained from experimental tensile tests were compared with the results of numerical analyses. The discrepancy between the numerical and experimental results was within an acceptable range (below 5%) for the dogbone specimen. 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