Fatigue response of additively manufactured as-built 15-5 PH stainless steel and effects of machining and thermal and surface treatments

Additively produced 15-5 PH stainless steel has wide industrial applications, but the combined effects of heat treatment, machining, and shot-peening and their order have not been deeply investigated. This topic is addressed here by a 2-by-3 experimental plan that has involved S–N curve and fatigue limit determination, using vertically built cylindrical samples, tested under rotating bending. The obtained responses have been analyzed by an ANOVA-based statistical approach for comparison of fatigue trends. Results indicate that heat treatment without machining may be even detrimental for fatigue due to embrittlement. Conversely, machining with subsequent shot-peening, even without heat treatment, has a remarkable impact and leads to a doubled fatigue strength with respect to as-built material. This strength is also quite close to that achievable for wrought material. The study has been completed by micrography and fractography, to reveal the dependence of microstructure, crack initiation sites, and failure mode on the performed treatments.