The vibration bending fatigue life uncertainty of additively manufactured Titanium (Ti) 6Al-4V specimens is studied. In this investigation, an analysis of microscopic discrepancies between 10 fatigued specimens paired by stress amplitude is correlated to the bending fatigue life scatter. Through scanning electron microscope (SEM) analysis of fracture surfaces and grain structures, anomalies and distinctions such as voids and grain geometries are identified in each specimen. This data along with previously published results are used to support assessments regarding bending fatigue uncertainty. Corrections on stress and scatter based on microscopic features are implemented to the stress versus fatigue life comparisons. The results of this investigation show that the bending fatigue life uncertainty can be bounded by cold-rolled Ti 6Al-4V data when correcting the tested stress amplitude values with stress concentration effects and variation due to microstructure geometries. The understanding gained from this study is important for future development of a predictive vibration bending fatigue life model that will include the probability of geometry, density, and location of voids as an artifact of LPBF build parameters.

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