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

Yoder, Sean L.; Morgan, Shawn; Kinzy, Corinne; Barnes, Erin; Kirka, Michael M.; Paquit, Vincent C.; Nandwana, Peeyush; Plotkowski, Alex J.; Dehoff, Ryan R.; Babu, Sudarsanam Suresh

doi:10.1016/j.addma.2017.12.001

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

Journal Article · Wed Dec 06 00:00:00 EST 2017 · Additive Manufacturing

DOI:https://doi.org/10.1016/j.addma.2017.12.001· OSTI ID:1458380

^[1]; Morgan, Shawn ^[1]; Kinzy, Corinne ^[1]; Barnes, Erin ^[1];

^[2];

^[2]; Plotkowski, Alex J. ^[2];

^[2]; Babu, Sudarsanam Suresh ^[3]

Univ. of Tennessee, Knoxville, TN (United States). Dept. of Mechanical, Aerospace and Biomedical Engineering
Oak Ridge National Lab. (ORNL), Oak Ridge, TN (United States). Manufacturing Demonstration Facility
Univ. of Tennessee, Knoxville, TN (United States). Dept. of Mechanical, Aerospace and Biomedical Engineering; Oak Ridge National Lab. (ORNL), Oak Ridge, TN (United States). Manufacturing Demonstration Facility

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. In conclusion, 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.

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Research Organization:: Oak Ridge National Lab. (ORNL), Oak Ridge, TN (United States)

Sponsoring Organization:: USDOE Office of Energy Efficiency and Renewable Energy (EERE)

Grant/Contract Number:: AC05-00OR22725

OSTI ID:: 1458380

Alternate ID(s):: OSTI ID: 1496476

Journal Information:: Additive Manufacturing, Vol. 19, Issue C; ISSN 2214-8604

Publisher:: ElsevierCopyright Statement

Country of Publication:: United States

Language:: English

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Cited by: 26 works

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References (23)

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Cited By (2)

Additive Manufacturing of Nickel Superalloys: Opportunities for Innovation and Challenges Related to Qualification Babu, S. S.; Raghavan, N.; Raplee, J. Metallurgical and Materials Transactions A, Vol. 49, Issue 9 https://doi.org/10.1007/s11661-018-4702-4	journal	June 2018
In Operando Monitoring by Analysis of Backscattered Electrons during Electron Beam Melting Arnold, Christopher; Böhm, Jonas; Körner, Carolin Advanced Engineering Materials, Vol. 22, Issue 9 https://doi.org/10.1002/adem.201901102	journal	December 2019

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

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