Extreme-value statistics reveal rare failure-critical defects in additive manufacturing

Boyce, Brad L.; Salzbrenner, Bradley C.; Rodelas, Jeffrey M.; Swiler, Laura P.; Madison, Jonathan D.; Jared, Bradley H.; Shen, Yu -Lin

doi:10.1002/adem.201700102

Title: Extreme-value statistics reveal rare failure-critical defects in additive manufacturing

Journal Article · Fri Apr 21 00:00:00 EDT 2017 · Advanced Engineering Materials

DOI:https://doi.org/10.1002/adem.201700102· OSTI ID:1343622

Boyce, Brad L. ^[1]; Salzbrenner, Bradley C. ^[1]; Rodelas, Jeffrey M. ^[1]; Swiler, Laura P. ^[1]; Madison, Jonathan D. ^[1]; Jared, Bradley H. ^[1]; Shen, Yu -Lin ^[2]

Sandia National Lab. (SNL-NM), Albuquerque, NM (United States)
Univ. of New Mexico, Albuquerque, NM (United States)

Additive manufacturing enables the rapid, cost effective production of large populations of material test coupons such as tensile bars. By adopting streamlined test methods including ‘drop-in’ grips and non-contact extensometry, testing these large populations becomes more efficient. Unlike hardness tests, the tensile test provides a direct measure of yield strength, flow properties, and ductility, which can be directly incorporated into solid mechanics simulations. In the present work, over 1000 nominally identical tensile tests were used to explore the effect of process variability on the mechanical property distributions of a precipitation hardened stainless steel, 17-4PH, produced by a laser powder bed fusion process, also known as direct metal laser sintering. With this large dataset, rare defects are revealed that affect only ~2% of the population, stemming from a single build lot of material. Lastly, the rare defects caused a substantial loss in ductility and were associated with an interconnected network of porosity.

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Research Organization:: Sandia National Lab. (SNL-NM), Albuquerque, NM (United States)

Sponsoring Organization:: USDOE National Nuclear Security Administration (NNSA)

Grant/Contract Number:: AC04-94AL85000

OSTI ID:: 1343622

Report Number(s):: SAND-2017-0719J; 650654

Journal Information:: Advanced Engineering Materials, Vol. 19, Issue 8; ISSN 1438-1656

Publisher:: WileyCopyright Statement

Country of Publication:: United States

Language:: English

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Cited by: 55 works

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Progress toward autonomous experimental systems for alloy development Boyce, Brad L.; Uchic, Michael D. MRS Bulletin, Vol. 44, Issue 4 https://doi.org/10.1557/mrs.2019.75	journal	April 2019

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