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Title: 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:
ORCiD logo [1];  [1];  [1];  [1]; ORCiD logo [2]; ORCiD logo [2]; ORCiD logo [2];  [2]; ORCiD logo [2];  [3]
  1. Univ. of Tennessee, Knoxville, TN (United States). Dept. of Mechanical, Aerospace and Biomedical Engineering
  2. Oak Ridge National Lab. (ORNL), Oak Ridge, TN (United States). Manufacturing Demonstration Facility
  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
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}
}

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Cited by: 4 works
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Works referencing / citing this record:

Additive Manufacturing of Nickel Superalloys: Opportunities for Innovation and Challenges Related to Qualification
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