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Title: Approach to qualification using E-PBF in-situ process monitoring in Ti-6Al-4V

Abstract

Traditional design and qualification methodologies for parts manufactured by traditional methods are being applied to Additive Manufacturing (AM) without understanding the nuances of the machines. While mapping process variables and tracking build data is helpful, some variables such as build geometry, support structure, and part melt order have not been researched in depth. Changing these variables can result in significant variations in material properties and defect structure such that the process appears to be unreliable compared to traditional manufacturing. Hence, this research focuses on the need to understand the effects of overlooked variables such as melt order and nested geometry on the distribution of defects and bulk material properties in Ti-6Al-4 V alloy builds manufactured using the Arcam AB ® electron beam powder bed fusion process 1. This work collected and analyzed process log data and near infrared (NIR) images for every layer to correlate trends in porosity formation and mechanical performance. The location of pores, while naturally stochastic, is greatly influenced by the cross-sectional area as detected by NIR images and correlates with the failure sites from uniaxial testing.

Authors:
ORCiD logo [1]; ORCiD logo [2]; ORCiD logo [2]; ORCiD logo [2];  [3]; ORCiD logo [2];  [1]
  1. Univ. of Tennessee, Knoxville, TN (United States); Oak Ridge National Lab. (ORNL), Oak Ridge, TN (United States)
  2. Oak Ridge National Lab. (ORNL), Oak Ridge, TN (United States)
  3. Univ. of Maine, Orono, ME (United States)
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), Advanced Manufacturing Office (EE-5A)
OSTI Identifier:
1546555
Grant/Contract Number:  
AC05-00OR22725
Resource Type:
Accepted Manuscript
Journal Name:
Additive Manufacturing
Additional Journal Information:
Journal Volume: 28; Journal Issue: C; Journal ID: ISSN 2214-8604
Publisher:
Elsevier
Country of Publication:
United States
Language:
English
Subject:
42 ENGINEERING; 36 MATERIALS SCIENCE; Additive manufacturing; Electron beam powder bed fusion; Ti-6Al-4V; Qualification; Microstructure; In-situ monitoring

Citation Formats

Yoder, S., Nandwana, P., Paquit, V., Kirka, M., Scopel, A., Dehoff, R. R., and Babu, S. S. Approach to qualification using E-PBF in-situ process monitoring in Ti-6Al-4V. United States: N. p., 2019. Web. doi:10.1016/j.addma.2019.03.021.
Yoder, S., Nandwana, P., Paquit, V., Kirka, M., Scopel, A., Dehoff, R. R., & Babu, S. S. Approach to qualification using E-PBF in-situ process monitoring in Ti-6Al-4V. United States. doi:10.1016/j.addma.2019.03.021.
Yoder, S., Nandwana, P., Paquit, V., Kirka, M., Scopel, A., Dehoff, R. R., and Babu, S. S. Sat . "Approach to qualification using E-PBF in-situ process monitoring in Ti-6Al-4V". United States. doi:10.1016/j.addma.2019.03.021.
@article{osti_1546555,
title = {Approach to qualification using E-PBF in-situ process monitoring in Ti-6Al-4V},
author = {Yoder, S. and Nandwana, P. and Paquit, V. and Kirka, M. and Scopel, A. and Dehoff, R. R. and Babu, S. S.},
abstractNote = {Traditional design and qualification methodologies for parts manufactured by traditional methods are being applied to Additive Manufacturing (AM) without understanding the nuances of the machines. While mapping process variables and tracking build data is helpful, some variables such as build geometry, support structure, and part melt order have not been researched in depth. Changing these variables can result in significant variations in material properties and defect structure such that the process appears to be unreliable compared to traditional manufacturing. Hence, this research focuses on the need to understand the effects of overlooked variables such as melt order and nested geometry on the distribution of defects and bulk material properties in Ti-6Al-4 V alloy builds manufactured using the Arcam AB ® electron beam powder bed fusion process1. This work collected and analyzed process log data and near infrared (NIR) images for every layer to correlate trends in porosity formation and mechanical performance. The location of pores, while naturally stochastic, is greatly influenced by the cross-sectional area as detected by NIR images and correlates with the failure sites from uniaxial testing.},
doi = {10.1016/j.addma.2019.03.021},
journal = {Additive Manufacturing},
number = C,
volume = 28,
place = {United States},
year = {2019},
month = {4}
}

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This content will become publicly available on April 20, 2020
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