Characterization of topology optimized Ti-6Al-4V components using electron beam powder bed fusion

S. Yoder, S. Morgan, C. Kinzy, E. Barnes, M. Kirka, V. Paquit, P. Nandwana, A. Plotkowski, R. R. Dehoff, S. S. Babu

Research output: Contribution to journalArticlepeer-review

35 Scopus citations

Abstract

The use of manufacturing to generate topology optimized components shows promise for designers. However, designers who assume that additive manufacturing follows traditional manufacturing techniques may be misled due to the nuances in specific techniques. Since commercial topology optimization software tools are neither designed to consider orientation of the parts nor large variations in properties, the goal of this research is to evaluate the limitations of an existing commercial topology optimization software (i.e. Inspire®) using electron beam powder bed fusion (i.e. Arcam®) to produce optimized Ti-6Al-4V alloy components. Emerging qualification tools from Oak Ridge National Laboratory including in-situ near-infrared imaging and log file data analysis were used to rationalize the final performance of components. While the weight savings of each optimized part exceeded the initial criteria, the failure loads and locations proved instrumental in providing insight to additive manufacturing with topology optimization. This research has shown the need for a comprehensive understanding of correlations between geometry, additive manufacturing processing conditions, defect generation, and microstructure for characterization of complex components such as those designed by topology optimization.

Original languageEnglish
Pages (from-to)184-196
Number of pages13
JournalAdditive Manufacturing
Volume19
DOIs
StatePublished - Jan 2018

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
  • Ti64
  • Topology optimization

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