Approach to qualification using E-PBF in-situ process monitoring in Ti-6Al-4V

S. Yoder, P. Nandwana, V. Paquit, M. Kirka, A. Scopel, R. R. Dehoff, S. S. Babu

Research output: Contribution to journalArticlepeer-review

37 Scopus citations

Abstract

Traditional design and qualification methodologies for parts manufactured by traditional methods are being applied to Additive Manufacturing (AM) without understanding the nuances of the machines. While mapping process variables and tracking build data is helpful, some variables such as build geometry, support structure, and part melt order have not been researched in depth. Changing these variables can result in significant variations in material properties and defect structure such that the process appears to be unreliable compared to traditional manufacturing. Therefore, this research focuses on the need to understand the effects of overlooked variables such as melt order and nested geometry on the distribution of defects and bulk material properties in Ti-6Al-4 V alloy builds manufactured using the Arcam AB ® electron beam powder bed fusion process Description of equipment vendor, Arcam AB, does not mean endorsement by the authors. This study collected and analyzed process log data and near infrared (NIR) images for every layer to correlate trends in porosity formation and mechanical performance. The location of pores, while naturally stochastic, is heavily influenced by the cross-sectional area as detected by NIR images and correlates with the failure sites from uniaxial testing.

Original languageEnglish
Pages (from-to)98-106
Number of pages9
JournalAdditive Manufacturing
Volume28
DOIs
StatePublished - Aug 2019

Funding

Research was sponsored the U.S. Department of Energy , Office of Energy Efficiency and Renewable Energy , Advanced Manufacturing Office , under contract DE-AC05-00OR22725 with UT-Battelle, LLC. Research at University of Tennessee, Knoxville is sponsored by the UT-ORNL Governor’s Chair program for Advanced Manufacturing and Senior Design Program of the Department of Mechanical, Aerospace, and Biomedical Engineering of the Tickle College of Engineering .

Keywords

  • Additive manufacturing
  • Electron beam powder bed fusion
  • In-situ monitoring
  • Microstructure
  • Qualification
  • Ti-6Al-4V

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