Additive manufacturing (AM) techniques1 can produce complex, high-value metal parts, with potential applications as critical parts, such as those found in aerospace components. The production of AM parts with consistent and predictable properties requires input materials (e.g., metal powders) with known and repeatable characteristics, which in turn requires standardized measurement methods for powder properties. First, based on our previous work, we assess the applicability of current standardized methods for powder characterization for metal AM powders. Then we present the results of systematic studies carried out on two different powder materials used for additive manufacturing: stainless steel and cobalt-chrome. The characterization of these powders is important in NIST efforts to develop appropriate measurements and standards for additive materials and to document the property of powders used in a NIST-led additive manufacturing material round robin. An extensive array of characterization techniques was applied to these two powders, in both virgin and recycled states. The physical techniques included laser diffraction particle size analysis, X-ray computed tomography for size and shape analysis, and optical and scanning electron microscopy. Techniques sensitive to structure and chemistry, including X-ray diffraction, energy dispersive analytical X-ray analysis using the X-rays generated during scanning electron microscopy, and X-Ray photoelectron spectroscopy were also employed. The results of these analyses show how virgin powder changes after being exposed to and recycled from one or more Direct Metal Laser Sintering (DMLS) additive manufacturing build cycles. In addition, these findings can give insight into the actual additive manufacturing process.
Additive manufacturing techniques can produce complex, high-value metal parts, with potential applications as critical metal components such as those found in aerospace engines and as customized biomedical implants. Material porosity in these parts is undesirable for aerospace parts - since porosity could lead to premature failure - and desirable for some biomedical implants - since surface-breaking pores allows for better integration with biological tissue. Changes in a part’s porosity during an additive manufacturing build may also be an indication of an undesired change in the build process. Here, we present efforts to develop an ultrasonic sensor for monitoring changes in the porosity in metal parts during fabrication on a metal powder bed fusion system. The development of well-characterized reference samples, measurements of the porosity of these samples with multiple techniques, and correlation of ultrasonic measurements with the degree of porosity are presented. A proposed sensor design, measurement strategy, and future experimental plans on a metal powder bed fusion system are also presented.
A test artifact, intended for standardization, is proposed for the purpose of evaluating the performance of additive manufacturing (AM) systems. A thorough analysis of previously proposed AM test artifacts as well as experience with machining test artifacts have inspired the design of the proposed test artifact. This new artifact is designed to provide a characterization of the capabilities and limitations of an AM system, as well as to allow system improvement by linking specific errors measured in the test artifact to specific sources in the AM system. The proposed test artifact has been built in multiple materials using multiple AM technologies. The results of several of the builds are discussed, demonstrating how the measurement results can be used to characterize and improve a specific AM system.
Additive manufacturing (AM) processes can produce highly complex and customized parts without the need for dedicated tooling and can produce parts directly from the part design information. These types of processes are poised to revolutionize the manufacturing industry, yet several challenges are currently preventing more widespread adoption of AM technologies. Among these challenges are metrology issues associated with the measurement and characterization of the metal powders used for AM systems. This article will describe the technical challenges and needs for characterizing metal AM powders, recent research efforts to address those needs, and current work to standardize characterization methods in ASTM and ISO, such as the recently released ASTM F3049, Standard Guide for Characterizing Properties of Metal Powders Used for Additive Manufacturing Processes.
Pore structures of additively manufactured metal parts were investigated with X-ray Computed Tomography (XCT). Disks made of a cobalt-chrome alloy were produced using laser-based powder bed fusion (PBF) processes. The additive manufacturing processing parameters (scan speed and hatch spacing) were varied in order to have porosities varying from 0.1% to 70% so as to see the effects of processing parameters on the formation of pores and cracks. The XCT images directly show three-dimensional (3D) pore structure, along with cracks. Qualitative visualization is useful; however, quantitative results depend on accurately segmenting the XCT images. Methods of segmentation and image analysis were carefully developed based, as much as possible, on aspects of the images themselves. These enabled quantitative measures of porosity, including how porosity varies in and across the build direction, pore size distribution, how pore structure varies between parts with similar porosity levels but different processing parameters, pore shape, and particle size distribution of un-melted powder trapped in pores. These methods could possibly serve as the basis for standard segmentation and image analysis methods for metallic additively manufactured parts, enabling accurate and reliable defect detection and quantitative measures of pore structure, which are critical aspects of qualification and certification.
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