Static failure analysis of a thin-walled hydraulic installation space manufactured by laser beam melting

Abstract Additive manufacturing enables lightweight hydraulic components with highly integrated flow channels and reduced wall thicknesses, but their structural reliability under high internal pressure remains insufficiently understood. In particular, thin-walled installation spaces, essential interfaces for valves and fittings, have not been systematically investigated. This study addresses this gap by combining nonlinear finite element analysis, analytical modeling, and experimental pressure testing to assess the static failure behavior of an hydraulic installation space manufactured by Laser Beam Melting in 316L stainless steel. Test specimens with 1 mm wall thickness were fabricated, mechanically characterized, and subjected to pressure testing up to 100 MPa. The results identify sealing surface deformation and O-ring extrusion as the dominant failure mode, with a median failure pressure of 68,7 MPa. While catastrophic rupture was not observed, elastic–ideal-plastic finite element analysis predictions (64 MPa) aligned closely with Barlow’s formula, providing a conservative design tool. In contrast, elastic–plastic finite element analysis incorporating strain hardening, predicted a burst pressure of 81,5 MPa that could not be validated experimentally. The findings demonstrate that laser beam melted thin-walled installation spaces can withstand nearly twice the maximum working pressure of common hydraulic systems, offering valuable baseline data for standardization and future qualification of additively manufactured hydraulic equipment.