An assessment of spall failure modes in laser powder bed fusion fabricated stainless steel 316L with low-volume intentional porosity

Koube, K. D.; Sloop, T.; Lamb, K.; Kacher, J.; Babu, S. S.; Thadhani, N. N.

doi:10.1063/5.0143744

An assessment of spall failure modes in laser powder bed fusion fabricated stainless steel 316L with low-volume intentional porosity

Journal Article · Wed May 10 00:00:00 EDT 2023 · Journal of Applied Physics

DOI:https://doi.org/10.1063/5.0143744· OSTI ID:1988628

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Georgia Institute of Technology, Atlanta, GA (United States)
Univ. of Tennessee, Knoxville, TN (United States); Oak Ridge National Laboratory (ORNL), Oak Ridge, TN (United States)

Here, this paper reports on spall failure and damage modes in Laser Powder Bed Fusion fabricated Stainless Steel 316L (SS316L) with intentional levels of low-volume (1–5 vol. %) porosity and pore sizes of 200, 350, and 500 μm. The fabricated specimens were subjected to uniaxial-strain plate-impact loading at ~4.5 GPa, to initiate incipient spall failure. Analysis of velocimetry profiles measured using multi-probe photon-Doppler velocimetry coupled with post-mortem analysis of soft-recovered samples reveals local suppression of spall failure (termed as spall-dominated) as a function of porosity, as the failure mechanism transitions from spall-centered tensile stress dominated to a pore-centered microstructure-dominated damage mode involving void/crack nucleation and growth at pre-existing pores. The critical porosity level where the suppression of spall failure is first observed, as well as the spall location, is dependent on both the volume fraction and the size of the initially fabricated pores. In samples of 500 μm pore size, the suppression of spall failure is observed with as little as 1 vol. % porosity, while samples with smaller pores (200 μm) still experience spall-centered tensile stress dominated failure with higher levels (5 vol. %) of porosity. In the case of pore-centered microstructure-dominated failure, spall damage can occur but the spall plane is shifted toward the rear free surface, or more generally in areas further away from the region with pores. Highly heterogeneous deformation twinning, shear banding, grain rotation, and cracking are observed in the vicinity of pre-existing pores and expected spall failure sites.

View Accepted Manuscript (DOE)

Research Organization:: Oak Ridge Y-12 Plant (Y-12), Oak Ridge, TN (United States)

Sponsoring Organization:: USDOE National Nuclear Security Administration (NNSA); Steel Founders Society of America; National Aeronautics and Space Administration (NASA); National Science Foundation (NSF)

Grant/Contract Number:: NA0001942; AC05-00OR22725

OSTI ID:: 1988628

Journal Information:: Journal of Applied Physics, Journal Name: Journal of Applied Physics Journal Issue: 18 Vol. 133; ISSN 0021-8979

Publisher:: American Institute of Physics (AIP)Copyright Statement

Country of Publication:: United States

Language:: English

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36 MATERIALS SCIENCE
EBSD
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scanning electron microscopy
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An assessment of spall failure modes in laser powder bed fusion fabricated stainless steel 316L with low-volume intentional porosity

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