skip to main content
OSTI.GOV title logo U.S. Department of Energy
Office of Scientific and Technical Information

Title: ICME Approach to Determining Critical Pore Size of IN718 Produced by Selective Laser Melting

Abstract

A degree of porosity is expected in additively manufactured (AM) materials. To aid in the qualification of AM materials, the smallest pore size that results in a debit in the fatigue performance is quantified. In the work presented herein, crystal plasticity simulations are used to identify the stress concentration around pores of various sizes, revealing that a single 20-mu m pore or two 10-mu m pores (with centers spaced 15 mu m apart) localize stress at the pore, as opposed to elsewhere in the microstructure. In situ microtomography and far-field high-energy x-ray diffraction microscopy were used to identify crack formation and the evolution of the grain-level micromechanical fields during cyclic loading. Eighteen cracks were observed (15 at pores, 3 at the surface) at highly stressed grains in a sample, although most did not propagate. The dominant crack was seen to originate from the free surface, which is rationalized by fracture mechanics.

Authors:
ORCiD logo [1];  [1];  [1];  [1];  [2];  [2]
  1. Purdue Univ., West Lafayette, IN (United States)
  2. Argonne National Lab. (ANL), Lemont, IL (United States)
Publication Date:
Research Org.:
Argonne National Laboratory (ANL), Argonne, IL (United States)
Sponsoring Org.:
USDOE Office of Science (SC), Basic Energy Sciences (BES); U.S. Department of Defense (DOD), Defense Advanced Research Projects Agency (DARPA)
OSTI Identifier:
1606248
Grant/Contract Number:  
AC02-06CH11357
Resource Type:
Journal Article: Accepted Manuscript
Journal Name:
JOM. Journal of the Minerals, Metals & Materials Society
Additional Journal Information:
Journal Volume: 72; Journal Issue: 1; Journal ID: ISSN 1047-4838
Publisher:
Springer
Country of Publication:
United States
Language:
English
Subject:
36 MATERIALS SCIENCE; IN718; additive manufacturing; crack initiation; crystal plasticity; fatigue; high energy X-ray diffraction; porosity; synchrotron based microtomography

Citation Formats

Sangid, Michael D., Ravi, Priya, Prithivirajan, Veerappan, Miller, Nolan A., Kenesei, Peter, and Park, Jun-Sang. ICME Approach to Determining Critical Pore Size of IN718 Produced by Selective Laser Melting. United States: N. p., 2019. Web. doi:10.1007/s11837-019-03910-0.
Sangid, Michael D., Ravi, Priya, Prithivirajan, Veerappan, Miller, Nolan A., Kenesei, Peter, & Park, Jun-Sang. ICME Approach to Determining Critical Pore Size of IN718 Produced by Selective Laser Melting. United States. https://doi.org/10.1007/s11837-019-03910-0
Sangid, Michael D., Ravi, Priya, Prithivirajan, Veerappan, Miller, Nolan A., Kenesei, Peter, and Park, Jun-Sang. 2019. "ICME Approach to Determining Critical Pore Size of IN718 Produced by Selective Laser Melting". United States. https://doi.org/10.1007/s11837-019-03910-0. https://www.osti.gov/servlets/purl/1606248.
@article{osti_1606248,
title = {ICME Approach to Determining Critical Pore Size of IN718 Produced by Selective Laser Melting},
author = {Sangid, Michael D. and Ravi, Priya and Prithivirajan, Veerappan and Miller, Nolan A. and Kenesei, Peter and Park, Jun-Sang},
abstractNote = {A degree of porosity is expected in additively manufactured (AM) materials. To aid in the qualification of AM materials, the smallest pore size that results in a debit in the fatigue performance is quantified. In the work presented herein, crystal plasticity simulations are used to identify the stress concentration around pores of various sizes, revealing that a single 20-mu m pore or two 10-mu m pores (with centers spaced 15 mu m apart) localize stress at the pore, as opposed to elsewhere in the microstructure. In situ microtomography and far-field high-energy x-ray diffraction microscopy were used to identify crack formation and the evolution of the grain-level micromechanical fields during cyclic loading. Eighteen cracks were observed (15 at pores, 3 at the surface) at highly stressed grains in a sample, although most did not propagate. The dominant crack was seen to originate from the free surface, which is rationalized by fracture mechanics.},
doi = {10.1007/s11837-019-03910-0},
url = {https://www.osti.gov/biblio/1606248}, journal = {JOM. Journal of the Minerals, Metals & Materials Society},
issn = {1047-4838},
number = 1,
volume = 72,
place = {United States},
year = {Mon Nov 11 00:00:00 EST 2019},
month = {Mon Nov 11 00:00:00 EST 2019}
}

Journal Article:
Free Publicly Available Full Text
Publisher's Version of Record

Citation Metrics:
Cited by: 18 works
Citation information provided by
Web of Science

Save / Share:

Works referenced in this record:

Fiducial marker application method for position alignment of in situ multimodal X-ray experiments and reconstructions
journal, March 2016


A rotational and axial motion system load frame insert for in situ high energy x-ray studies
journal, September 2015


High Energy X-ray Micro-tomography for the characterization of thermally fatigued GlidCop specimen
journal, March 2013


Identifying strain localization and dislocation processes in fatigued Inconel 718 manufactured from selective laser melting
journal, May 2018


Improvement of fatigue resistance and ductility of TiAl6V4 processed by selective laser melting
journal, June 2015


Fatigue and Damage in Structural Materials Studied by X-Ray Tomography
journal, August 2012


Fracture mechanics by three-dimensional crack-tip synchrotron X-ray microscopy
journal, March 2015


Effect of small defects on the fatigue strength of martensitic stainless steels
journal, October 2019


Fatigue performance evaluation of selective laser melted Ti–6Al–4V
journal, March 2014


DREAM.3D: A Digital Representation Environment for the Analysis of Microstructure in 3D
journal, April 2014


Application of √area-concept to assess fatigue strength of AlSi7Cu0.5Mg casted components
journal, November 2017


Quantitative X-ray tomography
journal, December 2013


Crystal plasticity simulations of microstructure-induced uncertainty in strain concentration near voids in brass
journal, February 2015


Correlation between porosity and processing parameters in TiAl6V4 produced by selective laser melting
journal, September 2016


NIH Image to ImageJ: 25 years of image analysis
journal, June 2012


The imaging of failure in structural materials by synchrotron radiation X-ray microtomography
journal, September 2017


Three-Dimensional X-Ray Diffraction Microscopy
book, January 2004


Effects of post-processing on cyclic fatigue response of a titanium alloy additively manufactured by electron beam melting
journal, January 2017


Predictive models for fatigue property of laser powder bed fusion stainless steel 316L
journal, May 2018


Strain tensor development in a single grain in the bulk of a polycrystal under loading
journal, April 2002


Finite‐Strain Elastic—Plastic Theory with Application to Plane‐Wave Analysis
journal, January 1967


The Influence of Porosity on Fatigue Crack Initiation in Additively Manufactured Titanium Components
journal, August 2017


Relating porosity to fatigue failure in additively manufactured alloy 718
journal, June 2018


Bounds and Self-Consistent Estimates for Creep of Polycrystalline Materials
journal, February 1976


Understanding fatigue crack growth in aluminum alloys by in situ X-ray synchrotron tomography
journal, December 2013


A comparison of different approaches for imaging cracks in composites by X-ray microtomography
journal, July 2016

  • Yu, B.; Bradley, R. S.; Soutis, C.
  • Philosophical Transactions of the Royal Society A: Mathematical, Physical and Engineering Sciences, Vol. 374, Issue 2071
  • https://doi.org/10.1098/rsta.2016.0037

Far-field high-energy diffraction microscopy: a tool for intergranular orientation and strain analysis
journal, July 2011


Uncertainty Quantification in the Mechanical Response of Crystal Plasticity Simulations
journal, June 2019


Additive manufacturing in the context of structural integrity
journal, January 2017


Determining grain resolved stresses in polycrystalline materials using three-dimensional X-ray diffraction
journal, April 2010


Measuring fatigue crack deflections via cracking of constituent particles in AA7050 via in situ x-ray synchrotron-based micro-tomography
journal, November 2018


Using machine learning and a data-driven approach to identify the small fatigue crack driving force in polycrystalline materials
journal, July 2018


Mechanism of porosity formation and influence on mechanical properties in selective laser melting of Ti-6Al-4V parts
journal, October 2018


Fatigue behavior of A356-T6 aluminum cast alloys. Part I. Effect of casting defects
journal, February 2001


The Effectiveness of Hot Isostatic Pressing for Closing Porosity in Titanium Parts Manufactured by Selective Electron Beam Melting
journal, March 2016


New opportunities for quantitative tracking of polycrystal responses in three dimensions
journal, August 2015


Overview of Materials Qualification Needs for Metal Additive Manufacturing
journal, January 2016


Effects of defects, inclusions and inhomogeneities on fatigue strength
journal, April 1994


A rotational and axial motion system load frame insert for in situ high energy x-ray studies
text, January 2015


Fracture Mechanics
journal, January 1975


A rotational and axial motion system load frame insert for in situ high energy x-ray studies
text, January 2015


Fracture mechanics
journal, July 1982