Quantification and certification of additive manufacturing materials and processes

Bae, Chang‐Jun; Diggs, Alisha; Ramachandran, Arathi

doi:10.1016/b978-0-12-812155-9.00006-2

Cited by 26 publications

(16 citation statements)

References 26 publications

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“…Primarily, the main challenge with all AM procedures is the reliability and repeatability of parts [8,9]. Due to the thermal cycles that are experienced by the part during the build process, residual stresses are induced, resulting in part distortions.…”

Section: Introductionmentioning

confidence: 99%

Residual Strain Predictions for a Powder Bed Fusion Inconel 625 Single Cantilever Part

Yang

Allen

London

et al. 2019

Integr Mater Manuf Innov

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The laser powder bed fusion (LPBF) process involves using a laser beam to selectively melt metal powder with a desired shape on a substrate to create a part layer-by-layer. As an Additive Manufacturing (AM) process, laser powder bed fusion (commonly referred to as selective laser melting-SLM) offers superior design freedom over conventional manufacturing methods and enables the production of complex, lightweight geometries with applications in the aerospace, automotive, and biomedical industries. In addition to enhanced design freedom, AM technologies provide improved material utilization and allow for reduced assembly needs. However, the reliability and repeatability of additively manufactured parts is a challenge to the wide-scale adoption of the technology for safety critical parts. A critical limitation of process optimization is the prediction and control of residual stresses, distortion, and microstructure evolution. This work focuses on the development and implementation of a numerical modeling technique for the prediction of residual strains within an Inconel 625 LPBF part. The model, using the SIMULIA Additive Manufacturing Scenario App, based on the Abaqus 2018 finite element solver, was developed and analyzed as part of a submission for the NIST AM Benchmark 2018. A sequentially coupled thermo-mechanical analysis was adopted to replicate the building conditions of a single cantilever beam built at the NIST laboratories. The results of the blind study were compared to X-ray diffraction (XRD) measurements of the physical build. The predicted three-dimensional residual strain field showed a high level of accuracy and the submission described in this paper received joint first prize in the residual elastic strain category of the NIST AM Benchmark 2018. The results presented in this paper reflect only findings before the benchmark measurements were posted on the NIST website.

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Section: Introductionmentioning

confidence: 99%

Residual Strain Predictions for a Powder Bed Fusion Inconel 625 Single Cantilever Part

Yang

Allen

London

et al. 2019

Integr Mater Manuf Innov

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“…Another anticipated challenge in the use of AM to directly fabricate PPE through shared digital designs is the inherent variability between AM machines, materials, and build parameters [ 21 ], which can affect the mechanical properties of the printed materials and the accuracy of the printed geometries. In FFF, processing parameters such as layer thickness [ 12 ], layer orientation [ 22 ], raster width and spacing [ 23 ], and filament feed rate [ 14 ] influence porosity, part quality, and performance.…”

Section: Introductionmentioning

confidence: 99%

Additively manufactured respirators: quantifying particle transmission and identifying system-level challenges for improving filtration efficiency

Bezek

Pan

Harb

et al. 2021

Journal of Manufacturing Systems

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“…At present, main limitations for such use of the AM are the lack of robust and mature inspection, quality control and quality assurance techniques and an incomplete knowledge of the relationships between process, part shape, microstructure, and properties, which makes extremely difficult to anticipate the resulting material resistance to different failure modes, such as fracture, impact, creep, and multiaxial fatigue 1 . These limitations currently reflect in an extremely long and costly certification process for parts acceptability 2 . In order to develop reliable criteria for structural integrity assessment of AM parts, the role of process‐induced defects must be understood.…”

Section: Introductionmentioning

confidence: 99%

High‐rate characterization of additively manufactured Ti‐6Al‐4V using Taylor cylinder impact test: Experiments

Iannitti

Bonora

Testa

et al. 2020

Mat Design & Process Comms

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Fracture behavior of additively manufactured (AM) Ti‐6Al‐4V has been investigated under quasistatic and impact loading. Taylor cylinder impact tests, on material printed along different directions, have been performed at various velocity to determine high‐rate material deformation and impact velocity for damage initiation. Test results revealed that, although the AM material under quasistatic loading condition shows better characteristics than the corresponding wrought material grade, under impact condition, fracture in AM material occurred at an impact velocity almost half of that of wrought grade and at a strain 10 time less of the quasistatic uniaxial fracture strain. Microscopy investigation seems to indicate that pre‐existing microvoids produced by the AM process promote shear band development under impact loading causing fracture at much lower strain.

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Quantification and certification of additive manufacturing materials and processes

Cited by 26 publications

References 26 publications

Residual Strain Predictions for a Powder Bed Fusion Inconel 625 Single Cantilever Part

Residual Strain Predictions for a Powder Bed Fusion Inconel 625 Single Cantilever Part

Additively manufactured respirators: quantifying particle transmission and identifying system-level challenges for improving filtration efficiency

High‐rate characterization of additively manufactured Ti‐6Al‐4V using Taylor cylinder impact test: Experiments

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