FAILURE INITIATION POINT CONTROL IN BLOWN POWDER DIRECTED ENERGY DEPOSITION

Alan Burl, Lauren Heinrich, Christopher Saldaña, Thomas Feldhausen

Research output: Chapter in Book/Report/Conference proceedingConference contributionpeer-review

Abstract

Additive manufacturing defects are often cited as being detrimental to the final product and significant effort has been expended to mitigate said defects. However, in applications where failure of the component is a necessity to prevent undo wear and tear, these defects may be leveraged as a mechanism to control part failure location. This work explored the use of varying deposition parameters to induce failure of a component at a specified location. A blown powder directed energy deposition system coupled with a five-axis machine tool was utilized for the manufacture of test specimens. A thin section of a part was intentionally deposited with parameters, namely laser power, outside those known to produce dense components in an attempt to introduce lack of fusion porosity. Porosity within the band was shown to vary with changing laser power. Hardness testing of the components showed a vertical gradient along the build direction. A slight increase in hardness of 25 HV is noted at 2 mm above the intended failure region. Micrographs of the failure region revealed a distinct boundary between the failure region and the nominally correct regions. This work has shown that porosity location can be controlled in a directed energy deposition process.

Original languageEnglish
Title of host publicationAdditive Manufacturing; Advanced Materials Manufacturing; Biomanufacturing; Life Cycle Engineering
PublisherAmerican Society of Mechanical Engineers (ASME)
ISBN (Electronic)9780791888100
DOIs
StatePublished - 2024
EventASME 2024 19th International Manufacturing Science and Engineering Conference, MSEC 2024 - Knoxville, United States
Duration: Jun 17 2024Jun 21 2024

Publication series

NameProceedings of ASME 2024 19th International Manufacturing Science and Engineering Conference, MSEC 2024
Volume1

Conference

ConferenceASME 2024 19th International Manufacturing Science and Engineering Conference, MSEC 2024
Country/TerritoryUnited States
CityKnoxville
Period06/17/2406/21/24

Funding

This research was supported in part by an appointment with the AMMTO Summer Internships program sponsored by the U.S. Department of Energy (DOE), EERE Advanced Materials and Manufacturing Technologies Office (AMMTO). This program is administered by the Oak Ridge Institute for Science and Education (ORISE) for DOE. ORISE is managed by ORAU. All opinions expressed in this paper are the author\u2019s and do not necessarily reflect the policies and views of DOE, ORAU, or ORISE. This manuscript has been authored by UT-Battelle, LLC, under contract DE-AC05-00OR22725 with the US Department of Energy (DOE). The US government retains and the publisher, by accepting the article for publication, acknowledges that the US government retains a nonexclusive, paid-up, irrevocable, worldwide license to publish or reproduce the published form of this manuscript, or allow others to do so, for US government purposes. DOE will provide public access to these results of federally sponsored research in accordance with the DOE Public Access Plan (http://energy.gov/downloads/doe-public-access-plan) The authors would like to acknowledge the cooperation and support of the Okuma Corporation, Open Mind Technologies LLC, and Carl Zeiss Industrial Metrology LLC. Additionally, the authors would like to thank Dennis Brown, Michael Mcalister, and Sarah Graham for their assistance in machine operation and preparation of samples for metallography.

Keywords

  • Additive Manufacturing
  • Directed Energy Deposition
  • Hybrid Manufacturing

Fingerprint

Dive into the research topics of 'FAILURE INITIATION POINT CONTROL IN BLOWN POWDER DIRECTED ENERGY DEPOSITION'. Together they form a unique fingerprint.

Cite this