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 language | English |
---|---|
Pages (from-to) | 98-106 |
Number of pages | 9 |
Journal | Additive Manufacturing |
Volume | 28 |
DOIs | |
State | Published - 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