Structural integrity of additive manufactured materials and parts

380 Pages·2020·70.359 MB·English

by  Nima Shamsaei (editor), Mohsen Seifi (editor)

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Selected Technical Papers
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ASTM INTERNATIONAL P
1
6
Helping our world work better 3 STP 1631
1
Editors:
Nima Shamsaei
ISBN: 978-0-8031-7708-6
Mohsen Seifi
Stock #: STP1631
www.astm.org
.
SELECTEDTECHNICALPAPERS
STP1631
Editors:NimaShamsaeiandMohsenSeifi
Structural Integrity of
Additive Manufactured
Materials and Parts
ASTM STOCK #STP1631
DOI: 10.1520/STP1631-EB
ASTMInternational,100BarrHarborDrive,POBoxC700,WestConshohocken,PA19428-2959
PrintedintheU.S.A.
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LibraryofCongressCataloging-in-PublicationData
Names:Shamsaei,Nima,editor.|Seifi,Mohsen,editor.
Title:Structuralintegrityofadditivemanufacturedmaterialsandparts/
editors,NimaShamsaei,MohsenSeifi.
Description:WestConshohocken,PA,USA:ASTMInternational,[2020]|
Series:Selectedtechnicalpapers;STP1631|Includesbibliographical
references.|Summary:“THISCOMPILATIONOFSelectedTechnicalPapers,
STP1631,StructuralIntegrityofAdditiveManufacturedMaterials&
Parts,containspeer-reviewedpapersthatwerepresentedatasymposium
heldOctober7–10,2019,inNationalHarbor,MD,USA.Thesymposiumwas
sponsoredbyASTMInternationalAdditiveManufacturingCenterof
ExcellenceandadditionalASTMTechnicalCommittees”–Providedby
publisher.
Identifiers:LCCN2020032340(print)|LCCN2020032341(ebook)|ISBN
9780803177086|ISBN9780803177093(pdf)
Subjects:LCSH:Strengthofmaterials.|Machineparts–Testing.|
Structuralanalysis(Engineering)|Additivemanufacturing.
Classification:LCCTA405.S7672020 (print)|LCCTA405 (ebook)|DDC
620.1/12–dc23
LCrecordavailableathttps://lccn.loc.gov/2020032340
LCebookrecordavailableathttps://lccn.loc.gov/2020032341
ISBN:978-0-8031-7708-6
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September,2020
Foreword
THIS COMPILATION OF Selected Technical Papers, STP1631, Structural Integrity
of Additive Manufactured Materials and Parts, contains peer-reviewed papers that
were presented at a symposium held October 7–10, 2019, in National Harbor, MD,
USA.The symposium was sponsoredbyASTMInternational AdditiveManufactur-
ingCenterofExcellenceandadditionalASTMTechnicalCommittees.
Symposium Chairs and STP Editors:
Nima Shamsaei
Auburn University
Auburn, AL, USA
Mohsen Seifi
ASTM International
Washington, DC, USA
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.
Contents
Overview ix
DemonstrationofClosed-LoopControlforLaserPowderBedFusion(LPBF) 1
DavidMaass
OntheChallengestowardRealizationofFunctionallyGradedStructuresby
ElectronBeamMelting—Fe-BaseShapeMemoryAlloyandStainlessSteel 20
ChristofTorrent,Andre´Bauer,MalteVollmer,andThomasNiendorf
ResidualStressFormationinLaser-BasedPowderBedFusion(PBF-LB)ofInvar36 34
MostafaYakoutandMohamedA.Elbestawi
OriginofOxidesandOxide-RelatedPoresinLaserPowderBedFusionParts 45
TomioOhtsuki,LonnieSmith,MingTang,andP.ChrisPistorius
TowardUnderstandingtheRoleofSurfaceTextureforAdditively
ManufacturedMetalParts 61
AdamJ.Brooks,ArushiDhakad,AgustinDiaz,andDanielKowalik
OptimizingX-RayComputedTomographySettingsforDimensionalMetrology
Using2DImageAnalysis 88
YounesChahid,AndrewTownsend,AlexanderLiu,PaulBills,
PhilipSperling,andRaduRacasan
ChallengesinInspectingInternalFeaturesforSLMAdditiveManufactured
BuildArtifacts 102
AhmedTawfik,RaduRacasan,DesiBacheva,LiamBlunt,
Andre´Beerlink,andPaulBills
ACriticalDiscussionontheDiffraction-BasedExperimentalDetermination
ofResidualStressinAMParts 122
TatianaMishurova,ItziarSerrano-Mun˜oz,TobiasFritsch,AlexanderUlbricht,
MaximilianSprengel,AlexanderEvans,ArneKromm,MauroMadia,
andGiovanniBruno
. v
X-RayComputedTomographyInspectioninMetalAdditiveManufacturing:
TheRoleofWitnessSpecimens 139
AntonduPlessis,JessM.Waller,StephanG.leRoux,InaYadroitsava,
IgorYadroitsev,JohanEls,andJacobusPrinsloo
PerspectiveonNondestructiveEvaluationofAdditiveManufacturedComponents 157
EricLindgrenandBryceJolley
PredictionofResidualStressEvolutionforEnd-To-EndProcessChainof
LaserPowderBedFusionProcessandDeterminationofFatigueS-NCurves 165
ShukriAfazov,JamieFrame,UtkarshaAnkalkhope,PrveenBidare,
YijunLiu,WilsonVesga,andBenDutton
DesignofCouponsandTestMethodologyforOrthotropicCharacterization
ofFFF-ProcessedUltem9085 176
TommyHyatt,RichardMartin,andRichFields
IntrinsicThresholdStressIntensityofAdditiveManufacturedMetals 188
R.Sunder,RameshKoraddi,andAndreiGorunov
AMultiscaleMaterialModelingApproachtoPredicttheMechanical
PropertiesofPowderBedFusion(PBF)Metal 203
YangLi,HongyiXu,Wei-JenLai,ZiangLi,andXumingSu
AlternateMethodforDeterminingYieldStrengthofPolymerAdditiveManufacturing 214
ChulY.Park,KeithE.Rupel,ChelseyE.Henry,KevinF.Malik,
SayataGhose,andUpulR.Palliyaguru
EffectsofSurfaceRoughnessandPorosityonFatigueBehaviorofAlSi10Mg
ProducedbyLaserPowderBedFusionProcess 229
Wei-JenLai,ZiangLi,AvineshOjha,YangLi,JoyForsmark,
CarlosEngler,andXumingSu
CharacterizationofFunctionallyGradedMaterialsBasedonInconel718
andStainlessSteel316LManufacturedbyDEDProcess 247
JanDˇzugan,DanielMelzer,MartinaKoukol´ıkova´,JaroslavVavˇr´ık,andMohsenSeifi
FrettingFatigueCharacterizationinPress-FitJointsofAMPartsby
X-RayTomographyandDigitalImageCorrelation 257
InigoBacaicoa,SaschaHorn,AngelikaBrueckner-Foit,
JuliaRichter,andThomasNiendorf
EffectofMicrostructureandInternalDefectsontheMechanical
PropertiesofTi6Al4VGyroidLatticeStructuresforBiomedicalImplants 271
DaliaMahmoud,MohamedA.Elbestawi,andKassimS.Al-Rubaie
Full-ScaleHigh-Load,Thermal,andFatigueTestingofAdditive
ManufacturedPowderBedFusionComponentforOilFieldApplications 289
MatthewWayneSanders,AdamRowe,andSureshDivi
. vi
DynamicCompressionResponseofPorousZirconium-BasedBulk
MetallicGlass(Zr Ti Cu Ni Be )Honeycomb:ANumericalStudy 308
41 14 12.5 10 22.5
NandKishoreSingh,ShashiKantKumar,SatishK.S.N.Idury,
K.K.Singh,andRatneshwarJha
PreclinicalTestingofaNovel,Additive-Manufactured,Three-Dimensional
PorousTitaniumStructure 322
ErikWoodard,ZachPost,andMarkMorrison
InvestigationofMicrostructureandMechanicalPropertiesofSLM-Produced
Inconel718andHastelloy-XAlloys 340
GuneyMertBilgin,CansinemTuzemen,CemreTigli,andYesimNurGulcan
AnalysisofDataStreamsforQualificationandCertificationofInconel738LC
AirfoilsProcessedthroughElectronBeamMelting 352
MichaelKirka,DerekRose,WilliamHalsey,AmirkoushyarZiabari,VincentPaquit,
DanielRyan,andPaulBrackman
. vii
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Overview
Toensurethestructuralintegrityofadditivelymanufactured(AM)parts,thereisa
need for establishing feedstock-process-structure-property-performance relation-
ships, specifically where these components and structures are being used in safety
criticalapplications.Therefore,theFourthASTMInternationalSymposiumonthe
StructuralIntegrity ofAdditive Manufactured Materials and Parts tookplace from
October 7–10, 2019, in the Washington, DC, area in coordination with partners
from government,industry, and academia, toprovide aforum for theexchange of
ideas regarding the structural integrity of parts fabricated using additive
manufacturingwithafocusonthelackofindustrystandards,designprinciples,as
wellasqualificationandcertificationchallenges.
The first event of this kind was sponsored by ASTM International Committee
E08 asaworkshop inSanAntonioin May2016. The second event was sponsored
by Committees E08 and F42 as a symposium in Atlanta in November 2017. The
third event was held in Washington, DC and sponsored by Committees F42, E08,
andE07inNovember2018.
AfterthecreationofASTMInternationalAdditiveManufacturingCenterofEx-
cellence(AMCoE)inearly2018andthegrowthoftheAMindustry,theefforthas
beencentralizedandisnowbeingledandsponsoredbytheAMCoE,involvingsev-
eral co-sponsoring ASTM technical committees, including: B09 on Metal Powders
and Metal Powder Products; D20 onPlastics; D30 on Composite Materials; E07 on
Nondestructive Testing; E08 on Fatigue and Fracture; F04 on Medical and Surgical
Materials and Devices; and F42 on Additive Manufacturing Technologies. In addi-
tion,thefourtheventwassupportedbytheNationalAeronauticsandSpaceAdmin-
istration(NASA),NationalInstituteofStandardsandTechnology(NIST),European
StructuralIntegritySociety(ESIS)TC15,andtheFoodandDrugAdministration.
This event continues to receive interest from the international community and
has been growing drastically, becoming the main gathering around standardization,
qualification, and certification for additively manufactured materials and parts. This
yearwearepleasedtoreportthatwehave133talks,including44invitedspeakers,10
posters, 25 student competition talks, 3 panel discussions, and over 300 attendees,
representingindustry,academia,andgovernmentfrommorethan30countries.
Thereare24selectedtechnicalpapers(STPs)inthiscollectionthatwillprovide
anopportunitytodelvemoredeeplyintothewidevarietyoftopicscoveredduring
the symposium. While individual papers often touch on multiple topics, the
. ix