AFRL Additive Manufacturing Modeling Series: Challenge 1, Characterization of Residual Strain Distribution in Additively-Manufactured Metal Parts Using Energy-Dispersive Diffraction
Abstract
A machine component fabricated by additive manufacturing (AM) of metal powders often possesses steep residual stress gradients with significant magnitudes due to large temperature gradients that transpire within a localized area during fabrication. These processing-induced residual stresses can cause distortion of the part, and if they are of significant magnitude, they could induce cracking of the component, degrade printability, and/or diminish subsequent mechanical performance. The ability to predict these residual stresses imparted by AM is an important step in permeating AM technology for advanced manufacturing. Calibration and validation of AM process models used for prediction are, therefore, a critical step in understanding the origin and mitigating the challenges associated with residual stresses inherent to the AM process. In the present work, the residual strain distributions in components with simple geometries fabricated by a laser powder bed fusion (LBPF) process were characterized non-destructively using energy-dispersive X-ray diffraction in support of the US Air Force Research Laboratory Additive Manufacturing Modeling Challenge Series Groeber et al. (JOM 70:441-448, 2018). The measurement setup and approach are described in detail so that the data can be used as a benchmark to calibrate and validate models for the prediction of macro-scale residual stresses due to themore »
- Authors:
-
[2]
- Argonne National Laboratory (ANL), Argonne, IL (United States)
- Air Force Research Laboratory (AFRL), Wright-Patterson AFB, OH (United States)
- The Ohio State University, Columbus, OH (United States)
- Publication Date:
- Research Org.:
- Argonne National Laboratory (ANL), Argonne, IL (United States)
- Sponsoring Org.:
- USDOE Office of Science (SC), Basic Energy Sciences (BES). Scientific User Facilities (SUF); US Air Force Office of Scientific Research (AFOSR)
- OSTI Identifier:
- 1996502
- Grant/Contract Number:
- AC02-06CH11357
- Resource Type:
- Accepted Manuscript
- Journal Name:
- Integrating Materials and Manufacturing Innovation
- Additional Journal Information:
- Journal Volume: 10; Journal Issue: 4; Journal ID: ISSN 2193-9764
- Publisher:
- Springer
- Country of Publication:
- United States
- Language:
- English
- Subject:
- 36 MATERIALS SCIENCE; EDXRD; additive manufacturing; energy-dispersive diffraction; laser powder bed fusion; residual strain; selective laser melting
Citation Formats
Chuang, Andrew C., Park, Jun-Sang, Shade, Paul A., Schwalbach, Edwin J., Groeber, Michael A., and Musinski, William D. AFRL Additive Manufacturing Modeling Series: Challenge 1, Characterization of Residual Strain Distribution in Additively-Manufactured Metal Parts Using Energy-Dispersive Diffraction. United States: N. p., 2021.
Web. doi:10.1007/s40192-021-00233-4.
Chuang, Andrew C., Park, Jun-Sang, Shade, Paul A., Schwalbach, Edwin J., Groeber, Michael A., & Musinski, William D. AFRL Additive Manufacturing Modeling Series: Challenge 1, Characterization of Residual Strain Distribution in Additively-Manufactured Metal Parts Using Energy-Dispersive Diffraction. United States. https://doi.org/10.1007/s40192-021-00233-4
Chuang, Andrew C., Park, Jun-Sang, Shade, Paul A., Schwalbach, Edwin J., Groeber, Michael A., and Musinski, William D. Mon .
"AFRL Additive Manufacturing Modeling Series: Challenge 1, Characterization of Residual Strain Distribution in Additively-Manufactured Metal Parts Using Energy-Dispersive Diffraction". United States. https://doi.org/10.1007/s40192-021-00233-4. https://www.osti.gov/servlets/purl/1996502.
@article{osti_1996502,
title = {AFRL Additive Manufacturing Modeling Series: Challenge 1, Characterization of Residual Strain Distribution in Additively-Manufactured Metal Parts Using Energy-Dispersive Diffraction},
author = {Chuang, Andrew C. and Park, Jun-Sang and Shade, Paul A. and Schwalbach, Edwin J. and Groeber, Michael A. and Musinski, William D.},
abstractNote = {A machine component fabricated by additive manufacturing (AM) of metal powders often possesses steep residual stress gradients with significant magnitudes due to large temperature gradients that transpire within a localized area during fabrication. These processing-induced residual stresses can cause distortion of the part, and if they are of significant magnitude, they could induce cracking of the component, degrade printability, and/or diminish subsequent mechanical performance. The ability to predict these residual stresses imparted by AM is an important step in permeating AM technology for advanced manufacturing. Calibration and validation of AM process models used for prediction are, therefore, a critical step in understanding the origin and mitigating the challenges associated with residual stresses inherent to the AM process. In the present work, the residual strain distributions in components with simple geometries fabricated by a laser powder bed fusion (LBPF) process were characterized non-destructively using energy-dispersive X-ray diffraction in support of the US Air Force Research Laboratory Additive Manufacturing Modeling Challenge Series Groeber et al. (JOM 70:441-448, 2018). The measurement setup and approach are described in detail so that the data can be used as a benchmark to calibrate and validate models for the prediction of macro-scale residual stresses due to the LPBF process.},
doi = {10.1007/s40192-021-00233-4},
journal = {Integrating Materials and Manufacturing Innovation},
number = 4,
volume = 10,
place = {United States},
year = {Mon Oct 25 00:00:00 EDT 2021},
month = {Mon Oct 25 00:00:00 EDT 2021}
}
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