Characterization of topology optimized Ti-6Al-4V components using electron beam powder bed fusion
Abstract
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.
- Authors:
-
[1];
[2];
[2];
[2];
[2];
- 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
- Publication Date:
- Research Org.:
- Oak Ridge National Lab. (ORNL), Oak Ridge, TN (United States)
- Sponsoring Org.:
- USDOE Office of Energy Efficiency and Renewable Energy (EERE)
- OSTI Identifier:
- 1458380
- Alternate Identifier(s):
- OSTI ID: 1496476
- Grant/Contract Number:
- AC05-00OR22725
- Resource Type:
- Accepted Manuscript
- Journal Name:
- Additive Manufacturing
- Additional Journal Information:
- Journal Volume: 19; Journal Issue: C; Journal ID: ISSN 2214-8604
- Publisher:
- Elsevier
- Country of Publication:
- United States
- Language:
- English
- Subject:
- 42 ENGINEERING; Additive manufacturing; Electron beam powder bed fusion; Ti64; Topology optimization
Citation Formats
Yoder, Sean L., Morgan, Shawn, Kinzy, Corinne, Barnes, Erin, Kirka, Michael M., Paquit, Vincent C., Nandwana, Peeyush, Plotkowski, Alex J., Dehoff, Ryan R., and Babu, Sudarsanam Suresh. Characterization of topology optimized Ti-6Al-4V components using electron beam powder bed fusion. United States: N. p., 2017.
Web. doi:10.1016/j.addma.2017.12.001.
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. Characterization of topology optimized Ti-6Al-4V components using electron beam powder bed fusion. United States. https://doi.org/10.1016/j.addma.2017.12.001
Yoder, Sean L., Morgan, Shawn, Kinzy, Corinne, Barnes, Erin, Kirka, Michael M., Paquit, Vincent C., Nandwana, Peeyush, Plotkowski, Alex J., Dehoff, Ryan R., and Babu, Sudarsanam Suresh. Wed .
"Characterization of topology optimized Ti-6Al-4V components using electron beam powder bed fusion". United States. https://doi.org/10.1016/j.addma.2017.12.001. https://www.osti.gov/servlets/purl/1458380.
@article{osti_1458380,
title = {Characterization of topology optimized Ti-6Al-4V components using electron beam powder bed fusion},
author = {Yoder, Sean L. and Morgan, Shawn and Kinzy, Corinne and Barnes, Erin and Kirka, Michael M. and Paquit, Vincent C. and Nandwana, Peeyush and Plotkowski, Alex J. and Dehoff, Ryan R. and Babu, Sudarsanam Suresh},
abstractNote = {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.},
doi = {10.1016/j.addma.2017.12.001},
journal = {Additive Manufacturing},
number = C,
volume = 19,
place = {United States},
year = {2017},
month = {12}
}
Free Publicly Available Full Text
Publisher's Version of Record
Other availability
Search WorldCat to find libraries that may hold this journal
Cited by: 26 works
Citation information provided by
Web of Science
Web of Science
Save to My Library
You must Sign In or Create an Account in order to save documents to your library.
Works referenced in this record:
LVIII. The limits of economy of material in frame-structures
journal, November 1904
- Michell, A. G. M.
- The London, Edinburgh, and Dublin Philosophical Magazine and Journal of Science, Vol. 8, Issue 47
Soil mechanics and plastic analysis or limit design
journal, January 1952
- Drucker, D. C.; Prager, W.
- Quarterly of Applied Mathematics, Vol. 10, Issue 2
Metal Additive Manufacturing: A Review
journal, April 2014
- Frazier, William E.
- Journal of Materials Engineering and Performance, Vol. 23, Issue 6
Additive manufacturing: Toward holistic design
journal, July 2017
- Jared, Bradley H.; Aguilo, Miguel A.; Beghini, Lauren L.
- Scripta Materialia, Vol. 135
Role of anisotropic properties on topology optimization of additive manufactured load bearing structures
journal, July 2017
- Zhang, Pu; Liu, Jikai; To, Albert C.
- Scripta Materialia, Vol. 135
Metal Additive Manufacturing: A Review of Mechanical Properties
journal, July 2016
- Lewandowski, John J.; Seifi, Mohsen
- Annual Review of Materials Research, Vol. 46, Issue 1
Additive manufacturing of metallic components by selective electron beam melting — a review
journal, March 2016
- Körner, C.
- International Materials Reviews, Vol. 61, Issue 5
Effect of microstructure and defects on fatigue behaviour of directed energy deposited Ti–6Al–4V
journal, June 2015
- Prabhu, A. W.; Vincent, T.; Chaudhary, A.
- Science and Technology of Welding and Joining, Vol. 20, Issue 8
The metallurgy and processing science of metal additive manufacturing
journal, March 2016
- Sames, W. J.; List, F. A.; Pannala, S.
- International Materials Reviews, Vol. 61, Issue 5
Microstructural evolution in laser-deposited multilayer Ti-6Al-4V builds: Part I. Microstructural characterization
journal, June 2004
- Kelly, S. M.; Kampe, S. L.
- Metallurgical and Materials Transactions A, Vol. 35, Issue 6
Microstructural evolution in laser-deposited multilayer Ti-6Al-4V builds: Part II. Thermal modeling
journal, June 2004
- Kelly, S. M.; Kampe, S. L.
- Metallurgical and Materials Transactions A, Vol. 35, Issue 6
Fabrication and microstructural characterisation of additive manufactured Ti-6Al-4V parts by electron beam melting: This paper reports that the microstructure and micro-hardness of an EMB part is thickness dependent
journal, October 2014
- Kok, Yihong; Tan, Xipeng; Tor, Shu Beng
- Virtual and Physical Prototyping, Vol. 10, Issue 1
Site specific control of crystallographic grain orientation through electron beam additive manufacturing
journal, November 2014
- Dehoff, R. R.; Kirka, M. M.; Sames, W. J.
- Materials Science and Technology, Vol. 31, Issue 8
Thermographic Microstructure Monitoring in Electron Beam Additive Manufacturing
journal, March 2017
- Raplee, J.; Plotkowski, A.; Kirka, M. M.
- Scientific Reports, Vol. 7, Issue 1
Numerical modeling of heat-transfer and the influence of process parameters on tailoring the grain morphology of IN718 in electron beam additive manufacturing
journal, June 2016
- Raghavan, Narendran; Dehoff, Ryan; Pannala, Sreekanth
- Acta Materialia, Vol. 112
Nucleation and growth of chimney pores during electron-beam additive manufacturing
journal, December 2016
- Cordero, Zachary C.; Dinwiddie, Ralph B.; Immel, David
- Journal of Materials Science, Vol. 52, Issue 6
Powder bed charging during electron-beam additive manufacturing
journal, February 2017
- Cordero, Zachary C.; Meyer, Harry M.; Nandwana, Peeyush
- Acta Materialia, Vol. 124
Falcon: Visual analysis of large, irregularly sampled, and multivariate time series data in additive manufacturing
journal, April 2017
- Steed, Chad A.; Halsey, William; Dehoff, Ryan
- Computers & Graphics, Vol. 63
Effects of heat treatments on microstructure and properties of Ti-6Al-4V ELI alloy fabricated by electron beam melting (EBM)
journal, February 2017
- Galarraga, Haize; Warren, Robert J.; Lados, Diana A.
- Materials Science and Engineering: A, Vol. 685
Microstructural modification of Ti–6Al–4V by using an in-situ printed heat sink in Electron Beam Melting® (EBM)
journal, December 2015
- Jamshidinia, M.; Atabaki, M. Mazar; Zahiri, M.
- Journal of Materials Processing Technology, Vol. 226
The Origin of Microstructural Diversity, Texture, and Mechanical Properties in Electron Beam Melted Ti-6Al-4V
journal, August 2010
- Al-Bermani, S. S.; Blackmore, M. L.; Zhang, W.
- Metallurgical and Materials Transactions A, Vol. 41, Issue 13
Support structure constrained topology optimization for additive manufacturing
journal, December 2016
- Mirzendehdel, Amir M.; Suresh, Krishnan
- Computer-Aided Design, Vol. 81
A new level-set based approach to shape and topology optimization under geometric uncertainty
journal, May 2011
- Chen, Shikui; Chen, Wei
- Structural and Multidisciplinary Optimization, Vol. 44, Issue 1
Works referencing / citing this record:
Additive Manufacturing of Nickel Superalloys: Opportunities for Innovation and Challenges Related to Qualification
journal, June 2018
- Babu, S. S.; Raghavan, N.; Raplee, J.
- Metallurgical and Materials Transactions A, Vol. 49, Issue 9
In Operando Monitoring by Analysis of Backscattered Electrons during Electron Beam Melting
journal, December 2019
- Arnold, Christopher; Böhm, Jonas; Körner, Carolin
- Advanced Engineering Materials, Vol. 22, Issue 9