As additive manufacturing (AM) is being adopted for cost-effectively fabricating metallic parts for safety-critical components subjected to fatigue loading, one of the major challenges has been on how to address structural significance of spatially distributed geometric discontinuities. To address some of the issues for pressure equipment applications, a DOE project was initiated to develop a robust metal AM flaw assessment methodology, aiming to examine the feasibility of extracting fatigue design stress allowable. This study was carried out in conjunction with ASME’s BPTCS/BNCS committee activities with test data both provided by some committee member organizations and resulted from a comprehensive literature search. This paper highlights both the technical approach adopted and major findings to date, including: (1) The master S-N curve (or E-N curve) method adopted by ASME BP&V Div 2 Code seems to provide an effective framework for extracting fatigue design stress allowable for fatigue evaluation for AM components; (2)A cost-effective AM flaw acceptance criterion can be implemented by identifying fatigue-critical locations or hot spots as defined in this study for a set of four typical components. (3) Fitness for Service (FFS) methodologies are shown effective in quantitatively establish flaw acceptance criteria for these hot spot locations.

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