Progress Towards Metal Additive Manufacturing Standardization to Support Qualification and Certification

Seifi, Mohsen; Gorelik, Michael; Waller, Jess; Hrabe, Nik; Shamsaei, Nima; Daniewicz, S.R.; Lewandowski, John J.

doi:10.1007/s11837-017-2265-2

Cited by 309 publications

(139 citation statements)

References 63 publications

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“…This can result in a distinction in thermal histories experienced by parts with different geometries/sizes, which can affect the microstructure, defect distributions, and material properties. Therefore, since AM parts with different sizes and/or geometries fabricated using identical process parameters and material may not exhibit similar mechanical behaviour, fatigue properties of small representative laboratory specimens may not accurately represent those of full‐scale parts . In addition, parts with complex geometries may experience variations in thermal history at different locations; thus, various microstructures and defect distributions may be expected within a part.…”

Section: Effects Of Geometry and Sizementioning

confidence: 99%

Fatigue behaviour of additive manufactured materials: An overview of some recent experimental studies on Ti‐6Al‐4V considering various processing and loading direction effects

Fatemi

Molaei

Simsiriwong

et al. 2019

Fatigue Fract Eng Mat Struct

Self Cite

151

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Although additive manufacturing (AM) has gained significant attention due to the advantages it offers and is currently a focus of much research, design of critical load carrying components utilizing such processes is still at its infancy. This is due to the fact that most of the load carrying components made by AM processes are subjected to cyclic loads, and fatigue behaviour of AM metals is far less understood as compared with those made by conventional methods, such as wrought and cast metals. To better understand the fatigue behaviour of AM metals, a wide range of issues that affect the behaviour in a synergistic manner must be considered. These include the effects of defects, residual stresses, surface finish, geometry and size, layer orientation, and heat treatment. Additionally, due to the multiaxial nature of the loading and/or complex geometries typically manufactured by AM processes, the stress state is often multiaxial including both normal and shear stresses. In this paper, the aforementioned effects influencing the fatigue resistance of AM parts, including torsion and multiaxial fatigue behaviour, are briefly discussed using some recently generated experimental data on Ti‐6Al‐4V by the authors.

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Section: Effects Of Geometry and Sizementioning

confidence: 99%

Fatigue behaviour of additive manufactured materials: An overview of some recent experimental studies on Ti‐6Al‐4V considering various processing and loading direction effects

Fatemi

Molaei

Simsiriwong

et al. 2019

Fatigue Fract Eng Mat Struct

Self Cite

151

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“…Ensuring part's quality is the main challenge for AM of real structural and functional parts. Variations in the AM systems, feedstock, and building procedures cause significant distinctions and uncertainties in the mechanical properties of AM materials . In addition, alteration of any of the involved parameters in the AM process, such as power setting, beam travel speed, and layer thickness, as well as the geometrical aspects of the part, affects the thermal histories during fabrication, and consequently, the microstructural features of the fabricated parts .…”

Section: Introductionmentioning

confidence: 99%

“…As a result, depending on the resultant microstructural details (ie, grain size, morphology, and texture) and defect characteristics (ie, type, size, shape, location, and distribution), the mechanical properties of AM materials can vary from machine to machine and even for different locations within a part . Despite the significant research efforts on the parameter optimization/control in AM process, fabricating a defect‐free part with uniform microstructure has not been fully achieved yet . Overcoming these challenges demands a thorough understanding of the relationships among process parameters, thermal history, solidification, resultant microstructure, and the mechanical behaviour of AM parts, which is still an open issue …”

Section: Introductionmentioning

confidence: 99%

“…Variations in the AM systems, feedstock, and building procedures cause significant distinctions and uncertainties in the mechanical properties of AM materials. [5][6][7][8] In addition, alteration of any of the involved parameters in the AM process, such as power setting, beam travel speed, and layer thickness, as well as the geometrical aspects of the part, affects the thermal histories during fabrication, and consequently, the microstructural features of the fabricated parts. 4,9 As a result, depending on the resultant microstructural details (ie, grain size, morphology, and texture) and defect characteristics (ie, type, size, shape, location, and distribution), the mechanical properties of AM materials can vary from machine to machine and even for different locations within a part.…”

Section: Introductionmentioning

confidence: 99%

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Fatigue life prediction of additively manufactured material: Effects of surface roughness, defect size, and shape

Yadollahi

Mahtabi

Khalili

et al. 2018

Fatigue Fract Eng Mat Struct

175

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In this paper, the effects of process‐induced voids and surface roughness on the fatigue life of an additively manufactured material are investigated using a crack closure‐based fatigue crack growth model. Among different sources of damage under cyclic loadings, fatigue because of cracks originated from voids and surface discontinuities is the most life‐limiting failure mechanism in the parts fabricated via powder‐based metal additive manufacturing (AM). Hence, having the ability to predict the fatigue behaviour of AM materials based on the void features and surface texture would be the first step towards improving the reliability of AM parts. Test results from the literature on Inconel 718 fabricated via a laser powder bed fusion (L‐PBF) method are analysed herein to model the fatigue behaviour based on the crack growth from semicircular/elliptical surface flaws. The fatigue life variations in the specimens with machined and as‐built surface finishes are captured using the characteristics of voids and surface profile, respectively. The results indicate that knowing the statistical range of defect size and shape along with a proper fatigue analysis approach provides the opportunity of predicting the scatter in the fatigue life of AM materials. In addition, maximum valley depth of the surface profile can be used as an appropriate parameter for the fatigue life prediction of AM materials in their as‐built surface condition.

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“…[250] Fatigue tests should reference ASTM E466 [251] and ISO 1099 [252] for high cycle fatigue or ASTM E606/E606M [253] and ISO 12106 [254] for low cycle fatigue. [241] Copyright 2017, Springer Nature. Classification of parts produced by AM intended for aerospace applications.…”

Section: Testing Requirementsmentioning

confidence: 99%

Laser‐Based Additive Manufacturing Technologies for Aerospace Applications

2019

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Additive manufacturing (AM) is a transformative technology that has rapidly grown over the past decade. AM processes build parts layer by layer and have found applications in the aerospace, biomedical, and automotive fields. The technology holds particular promise for the aerospace industry due to the reduced process time, weight savings of parts, and opportunities for new material development. Herein, a review of laser-based AM processes, existing AM systems, and aerospace parts being fabricated is presented. It further explores the material properties and microstructure of printed samples with both powder bed fusion and direct energy deposition processes. The benefits and challenges associated with the widespread use of the technology are discussed with emphases on the aerospace sector. Finally, the steps required for parts produced by AM processes to become certified for use in aerospace applications are presented.

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Progress Towards Metal Additive Manufacturing Standardization to Support Qualification and Certification

Cited by 309 publications

References 63 publications

Fatigue behaviour of additive manufactured materials: An overview of some recent experimental studies on Ti‐6Al‐4V considering various processing and loading direction effects

Fatigue behaviour of additive manufactured materials: An overview of some recent experimental studies on Ti‐6Al‐4V considering various processing and loading direction effects

Fatigue life prediction of additively manufactured material: Effects of surface roughness, defect size, and shape

Laser‐Based Additive Manufacturing Technologies for Aerospace Applications

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