Structural integrity of additive manufactured materials and parts

✍ Scribed by Nima Shamsaei (editor); Mohsen Seifi (editor)

• Publisher: ASTM International
• Year: 2020
• Tongue: English
• Leaves: 380
• Series: Journal of ASTM International
• Category: Library

✦ Synopsis

THIS COMPILATION OF Selected Technical Papers, STP1631, Structural Integrity of Additive Manufactured Materials and Parts, contains peer-reviewed papers that were presented at a symposium held October 7-10, 2019, in National Harbor, MD, USA. The symposium was sponsored by ASTM International Additive Manufacturing Center of Excellence and additional ASTM Technical Committees.

Symposium Chairs and STP Editors:

Nima Shamsaei
Auburn University
Auburn, AL, USA

Mohsen Seifi
ASTM International
Washington, DC, USA

TABLE OF CONTENTS

Overview

Demonstration of Closed-Loop Control for Laser Powder Bed Fusion (LPBF)

On the Challenges toward Realization of Functionally Graded Structures by Electron Beam Melting---Fe-Base Shape Memory Alloy and Stainless Steel

Residual Stress Formation in Laser-Based Powder Bed Fusion (PBF-LB) of Invar 36

Origin of Oxides and Oxide-Related Pores in Laser Powder Bed Fusion Parts

Toward Understanding the Role of Surface Texture for Additively Manufactured Metal Parts

Optimizing X-Ray Computed Tomography Settings for Dimensional Metrology Using 2D Image Analysis

Challenges in Inspecting Internal Features for SLM Additive Manufactured Build Artifacts

A Critical Discussion on the Diffraction-Based Experimental Determination of Residual Stress in AM Parts

X-Ray Computed Tomography Inspection in Metal Additive Manufacturing: The Role of Witness Specimens

Perspective on Nondestructive Evaluation of Additive Manufactured Components

Prediction of Residual Stress Evolution for End-To-End Process Chain of Laser Powder Bed Fusion Process and Determination of Fatigue S-N Curves

Design of Coupons and Test Methodology for Orthotropic Characterization of FFF-Processed Ultem 9085

Intrinsic Threshold Stress Intensity of Additive Manufactured Metals

A Multiscale Material Modeling Approach to Predict the Mechanical Properties of Powder Bed Fusion (PBF) Metal

Alternate Method for Determining Yield Strength of Polymer Additive Manufacturing

Effects of Surface Roughness and Porosity on Fatigue Behavior of AlSi10Mg Produced by Laser Powder Bed Fusion Process

Characterization of Functionally Graded Materials Based on Inconel 718 and Stainless Steel 316L Manufactured by DED Process

Fretting Fatigue Characterization in Press-Fit Joints of AM Parts by X-Ray Tomography and Digital Image Correlation

Effect of Microstructure and Internal Defects on the Mechanical Properties of Ti6Al4V Gyroid Lattice Structures for Biomedical Implants

Full-Scale High-Load, Thermal, and Fatigue Testing of Additive Manufactured Powder Bed Fusion Component for Oil Field Applications

Metallic Glass (Zr41Ti14Cu12.5Ni10Be22.5) Honeycomb: A Numerical Study

Preclinical Testing of a Novel, Additive-Manufactured, Three-Dimensional Porous Titanium Structure

Investigation of Microstructure and Mechanical Properties of SLM-Produced Inconel 718 and Hastelloy-X Alloys

Analysis of Data Streams for Qualification and Certification of Inconel 738LC Airfoils Processed through Electron Beam Melting

✦ Table of Contents

Cover
Title Page
Copyright Page
Foreword
Contents
Overview
Demonstration of Closed-Loop Control for Laser Powder Bed Fusion (LPBF)
Introduction
Surface Profilometry Data Acquisition
AS-FORMED QUALITY METRIC
SENSOR
BED SURFACE PROFILOMETRY
LAYER TOPOGRAPHIC MAPPING (LTM) IN SITU INSPECTION ALGORITHM
Test Coupon Fabrication
MATERIAL
PROCESS PARAMETERS
GENERATION OF SEEDED FLAWS
FLAW REPAIR PROCESS DEFINITION
FLAW COUPON CONFIGURATION
Validation of Flaws via CT Scan
CT POROSITY DATA PROCESSING
Automated Flaw Detection and Repair Demonstration (Closed-Loop Control)
Results and Discussion
LOF FLAW CREATION
LTM FLAW DETECTION ACCURACY
LOF FLAW REPAIR PROCESSES DEVELOPED
CLOSED-LOOP CONTROL DEMONSTRATION RESULTS
Conclusions
ACKNOWLEDGMENTS
References
On the Challenges toward Realization of Functionally Graded Structures by Electron Beam Melting—Fe-Base Shape Memory Alloy and Stainless Steel
Introduction
Materials and Experimental Methods
Results and Discussion
MICROSTRUCTURAL CHARACTERIZATION OF THE AS-BUILT STATE
MICROSTRUCTURAL CHARACTERIZATION AFTER DIFFERENT HEAT TREATMENTS
INCREMENTAL STRAIN TEST
Conclusions
ACKNOWLEDGMENTS
References
Residual Stress Formation in Laser-Based Powder Bed Fusion (PBF-LB) of Invar 36
Introduction
Materials and Methods
FEEDSTOCK MATERIAL AND PROCESS CONDITIONS
FINITE ELEMENT ANALYSIS
EXPERIMENTAL WORK
Results and Discussion
RESIDUAL STRESS OF INVAR 36
DEFLECTION OF INVAR 36 CANTILEVERS
Conclusions
ACKNOWLEDGMENTS
References
Origin of Oxides and Oxide-Related Pores in Laser Powder Bed Fusion Parts
Introduction
Possible Oxide Sources
OXIDE FILM ON METAL POWDER
SPATTER OXIDATION
SURFACE CONCENTRATION OF OXIDES
Conclusion
ACKNOWLEDGMENTS
References
Toward Understanding the Role of Surface Texture for Additively Manufactured Metal Parts
Introduction
Surface Texture
Additive Manufacturing and Surface Finishing
Current State Challenges
APPLICATION CHALLENGES
MEASUREMENT CHALLENGES
ANALYSIS CHALLENGES
Conclusions and Future Direction
ACKNOWLEDGMENTS
References
Optimizing X-Ray Computed Tomography Settings for Dimensional Metrology Using 2D Image Analysis
Introduction
CURRENT PROCEDURES AND CHALLENGES WHEN CHOOSING XCT SETTINGS
EVALUATING 2D IMAGE QUALITY OF XCT PROJECTIONS OR RECONSTRUCTIONS
Methodology
INTRODUCTION
THE DIMENSIONAL WORKPIECE
LATTICE STRUCTURE AND FIXTURING
XCT MEASUREMENT PROTOCOL
2D XCT MEASUREMENTS
3D VOLUME XCT SCANS AND ANALYSIS
Results
2D XCT PROJECTION ANALYSIS
3D XCT SCAN RESULTS AND MEASUREMENTS USED FOR VALIDATION
Discussion
Conclusion
ACKNOWLEDGEMENTS
Appendix
References
Challenges in Inspecting Internal Features for SLM Additive Manufactured Build Artifacts
Introduction
Study Rationale
Methodology
Results
Discussion
Conclusions
Appendix
CT Settings
References
A Critical Discussion on the Diffraction-Based Experimental Determination of Residual Stress in AM Parts
Introduction
Materials and Methods
DIFFRACTION-BASED DETERMINATION OF RESIDUAL STRESS
Results and Discussion
CHOICE OF THE APPROPRIATE ELASTIC CONSTANTS
CHOICE OF THE APPROPRIATE STRAIN-FREE REFERENCE d0
PROPER DETERMINATION OF THE PRINCIPAL AXES
SAMPLE ALIGNMENT
Concluding Remarks
ACKNOWLEDGMENTS
References
X-Ray Computed Tomography Inspection in Metal Additive Manufacturing: The Role of Witness Specimens
Introduction
Methods
Results and Discussion
PROCESS POROSITY DISTRIBUTIONS
STOP-START FLAW
Conclusions
ACKNOWLEDGMENTS
References
Perspective on Nondestructive Evaluation of Additive Manufactured Components
Introduction
Overview of Durability and Damage Tolerance
Structures Bulletin EZ-SB-19-01
Considerations for NDE/I
Validation of NDE/I Capability: Probability of Detection
Concluding Comments
ACKNOWLEDGMENTS
References
Prediction of Residual Stress Evolution for End-To-End Process Chain of Laser Powder Bed Fusion Process and Determination of Fatigue S-N Curves
Introduction
Endurance Limit Approach
Prediction of Residual Stresses in L-PBF Process Chains
Prediction of Fatigue S-N Curves
Conclusions
ACKNOWLEDGMENTS
References
Design of Coupons and Test Methodology for Orthotropic Characterization of FFF Processed Ultem 9085
Introduction
Manufacturing Repeatability
Mechanical Properties
FFF Construction Techniques
Orthotropy
Project Summary
Coupon Design-Pathfinding
CONTOUR VERSUS RASTER
EDGE AND SURFACE EFFECTS
MACHINING APPROACH
IN-PLANE TENSILE COUPONS
Z-DIRECTION TENSILE COUPONS
SHEAR COUPONS
COMPRESSION COUPONS
Dimensional Inspection and Mechanical Testing
Minimum Test Matrix Size for Statistical Evaluation
Discussion of Results, Conclusions, and Future Work
References
Intrinsic Threshold Stress Intensity of Additive Manufactured Metals
Introduction
Experimental Procedure
MATERIAL AND TEST COUPONS
TEST PROCEDURE
Test Results and Discussion
Conclusions
ACKNOWLEDGMENTS
References
A Multiscale Material Modeling Approach to Predict the Mechanical Properties of Powder Bed Fusion (PBF) Metal
Introduction
Methodology
MECHANICAL TESTING AND MICROSTRUCTURE CHARACTERIZATION
DEVELOPMENT OF THE MULTISCALE MATERIAL MODELS
Results and Discussions
RESULTS OF MICROSTRUCTURE CHARACTERIZATION AND MECHANICAL TESTING
CRYSTAL PLASTICITY PARAMETERS AND COMPARISON BETWEEN PREDICTION AND TESTING
LIMITATIONS OF THE CURRENT WORK AND PLANNED IMPROVEMENT
Conclusions
ACKNOWLEDGMENTS
References
Alternate Method for Determining Yield Strength of Polymer Additive Manufacturing
Introduction
Motivation of Research
Research Approach
SPECIMEN CONDITIONING
BASELINE TENSILE TEST
MULTILOAD TENSILE TEST
YIELD POINT CHECK TEST
Results
BASELINE TEST RESULTS
MULTILOAD TEST RESULTS
YIELD CHECK TEST RESULTS
Summary and Conclusion
ACKNOWLEDGMENTS
References
Effects of Surface Roughness and Porosity on Fatigue Behavior of AlSi10Mg Produced by Laser Powder Bed Fusion Process
Introduction
Experimental Procedure
MATERIALS AND LASER PARAMETERS
FATIGUE TEST
Results
MICROSTRUCTURE AND HARDNESS
EFFECT OF SURFACE ROUGHNESS ON FATIGUE PROPERTY
EFFECT OF DEFECTS ON FATIGUE PROPERTIES
Discussion
EFFECT OF SURFACE ROUGHNESS ON FATIGUE PROPERTY
EFFECT OF DEFECTS ON FATIGUE PROPERTY
Conclusions
References
Characterization of Functionally Graded Materials Based on Inconel 718 and Stainless Steel 316L Manufactured by DED Process
Introduction
Experimental
Results
POROSITY
LIGHT MICROSCOPY
EDS ANALYSIS
HARDNESS MEASUREMENT
TENSILE TESTS
Results Discussion
Conclusion
ACKNOWLEDGMENTS
References
Fretting Fatigue Characterization in Press-Fit Joints of AM Parts by X-Ray Tomography and Digital Image Correlation
Introduction
Materials and Methods
Results and Discussion
MATERIAL CHARACTERIZATION
DAMAGE BEHAVIOR
Conclusions
References
Effect of Microstructure and Internal Defects on the Mechanical Properties of Ti6Al4V Gyroid Lattice Structures for Biomedical Implants
Introduction
Materials and Methods
DESIGN AND 3D PRINTING
MECHANICAL TESTING
FINITE ELEMENT ANALYSIS
Results and Discussion
MICROSTRUCTURE
MORPHOLOGY
MECHANICAL PROPERTIES
Conclusions
ACKNOWLEDGMENTS
References
Full-Scale High-Load, Thermal, and Fatigue Testing of Additive Manufactured Powder Bed Fusion Component for Oil Field Applications
Introduction
Materials and Methods
METALLURGICAL CHARACTERIZATION
ELECTROCHEMICAL CORROSION TESTING
FULL-SCALE TESTING
Results and Discussion
ACKNOWLEDGMENTS
References
Dynamic Compression Response of Porous Zirconium-Based Bulk Metallic Glass (Zr41Ti14Cu12.5Ni10Be22.5) Honeycomb: A Numerical Study
Introduction
Simulation Methodology
Result and Discussion
STRESS–STRAIN ANALYSIS
ENERGY–TIME CURVE ANALYSIS
Conclusions
References
Preclinical Testing of a Novel, Additive-Manufactured, Three-Dimensional Porous Titanium Structure
Introduction
Material and Methods
MATERIAL
MATERIAL TESTING—COUPONS
MATERIAL TESTING—PORE MORPHOLOGY
MATERIAL TESTING—MECHANICAL PROPERTIES
MATERIAL TESTING—BONE INGROWTH
DEVICE TESTING—ACETABULAR SHELL DEFORMATION
DEVICE TESTING—FINITE ELEMENT ANALYSIS AND WORST-CASE DETERMINATION
DEVICE TESTING—ACETABULAR SHELL FATIGUE
DEVICE TESTING—SHELL AND AUGMENT FATIGUE
DEVICE TESTING—SCREW HOLE FEATURE STRENGTH
Results
Discussion
References
Investigation of Microstructure and Mechanical Properties of SLM-Produced Inconel 718 and Hastelloy-X Alloys
Introduction
Materials and Methods
Results and Discussion
INVESTIGATIONS OF CHEMICAL AND PHYSICAL PROPERTIES
MICROSTRUCTRAL INVESTIGATIONS
MECHANICAL BEHAVIOR OF THE SAMPLES
Conclusion
ACKNOWLEDGMENTS
References
Analysis of Data Streams for Qualification and Certification of Inconel 738LC Airfoils Processed through Electron Beam Melting
Introduction
Data Streams
Build Program and Inspection
Data Curation
Approach
U-NET FOR DEFECT SEGMENTATION
PREDICTION POST-PROCESSING
MAPPING LOG FILE DATA
Results and Discussion
Conclusions and FutureWork
ACKNOWLEDGMENTS
References
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