Abstract
It is widely accepted that gas porosity and lack-of-fusion flaws can degrade both static and dynamic mechanical performance of additively manufactured components, limiting the use of AM components in critical applications. However, the mechanisms by which these flaws form are still debated, and their impact on dynamic material performance have yet to be fully quantified. This work outlines the current understanding of the formation mechanisms for gas porosity, lack-of-fusion, and flaws related to melt pool instabilities. Where possible, the spatial and morphological characteristics of these flaws are highlighted, as well as their impact on mechanical properties. The effect of hot isostatic pressing is also discussed.
| Original language | English |
|---|---|
| Article number | 101457 |
| Journal | Additive Manufacturing |
| Volume | 36 |
| DOIs | |
| State | Published - Dec 2020 |
| Externally published | Yes |
Funding
This effort was performed through the National Center for Defense Manufacturing and Machining under the America Makes Program entitled “Understanding Stochastic Powder Bed Fusion Additive Manufacturing Flaw Formation and Impact on Fatigue” and is based on research sponsored by Air Force Research Laboratory under agreement number FA8650-16-2-5700 . The U.S. Government is authorized to reproduce and distribute reprints for Government purposes notwithstanding any copyright notation thereon. The authors would also like to acknowledge Dr. Jan Petrich for his contributions to the automated defect recognition algorithm, as well as Dr. Jay Keist, Dr. Dave Corbin, and Brett Diehl for their discussions with the authors. The authors would also like to thank Ryan Overdorff and 3D Systems for their approval to utilize sponsored data.
| Funders | Funder number |
|---|---|
| National Center for Defense Manufacturing and Machining | |
| Air Force Research Laboratory | FA8650-16-2-5700 |
Keywords
- Additive manufacturing
- Defects
- Flaws
- Powder bed fusion
