Scientific Foundations and Approaches for Qualification of Additively Manufactured Structural Components

Kramer, Sharlotte LorraineBolyard; LeBrun, Tyler Christopher; Pegues, Jonathan Wesley

doi:10.1007/s11837-024-06390-z

Scientific Foundations and Approaches for Qualification of Additively Manufactured Structural Components

Journal Article · Sun Feb 04 23:00:00 EST 2024 · JOM. Journal of the Minerals, Metals & Materials Society

DOI:https://doi.org/10.1007/s11837-024-06390-z· OSTI ID:2311254

^[1]; LeBrun, Tyler Christopher ^[2]; Pegues, Jonathan Wesley ^[3]

Sandia National Laboratories (SNL-NM), Albuquerque, NM (United States). Experimental Solid Mechanics
Sandia National Laboratories (SNL-CA), Livermore, CA (United States). R&D Systems Engineering
Sandia National Laboratories (SNL-NM), Albuquerque, NM (United States). Advanced Metal Processing

Additive manufacturing (AM) maintains a wide process window that enables complex designs otherwise unattainable via conventional production technologies. However, the lack of confidence in qualifying AM parts that leverage AM process–structure–property–performance (PSPP) relationships stymies design optimization and adoption of AM. While continuing efforts to map fundamental PSPP relationships that cover the potential design space, we first need pragmatic and then long-term solutions that overcome challenges associated with qualifying AM-designed parts. Two pragmatic solutions include: (1) AM material specifications to substantiate process reproducibility, and (2) component risk categorization to associate system risk relative to part performance and required part quality. A novel qualification paradigm under development involves efficient prediction of part performance over wide-ranging PSPP relationships through targeted testing and computational simulation. Here this paper describes projects at Sandia National Laboratories on PSPP relationship discovery, these pragmatic approaches, and the novel qualification approach.

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

Sponsoring Organization:: USDOE National Nuclear Security Administration (NNSA), Office of Defense Programs (DP)

Grant/Contract Number:: NA0003525

OSTI ID:: 2311254

Report Number(s):: SAND--2024-01563J

Journal Information:: JOM. Journal of the Minerals, Metals & Materials Society, Journal Name: JOM. Journal of the Minerals, Metals & Materials Society Journal Issue: Materials Vol. Online Pub; ISSN 1047-4838

Publisher:: SpringerCopyright Statement

Country of Publication:: United States

Language:: English

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Scientific Foundations and Approaches for Qualification of Additively Manufactured Structural Components

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