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

Yoder, S.; Nandwana, P.; Paquit, V.; Kirka, M.; Scopel, A.; Dehoff, R. R.; Babu, S. S.

doi:10.1016/j.addma.2019.03.021

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

Journal Article · Sat Apr 20 00:00:00 EDT 2019 · Additive Manufacturing

DOI:https://doi.org/10.1016/j.addma.2019.03.021· OSTI ID:1546555

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Univ. of Tennessee, Knoxville, TN (United States); Oak Ridge National Lab. (ORNL), Oak Ridge, TN (United States)
Oak Ridge National Lab. (ORNL), Oak Ridge, TN (United States)
Univ. of Maine, Orono, ME (United States)

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.

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Research Organization:: Oak Ridge National Laboratory (ORNL), Oak Ridge, TN (United States)

Sponsoring Organization:: USDOE Office of Energy Efficiency and Renewable Energy (EERE), Energy Efficiency Office. Advanced Manufacturing Office

Grant/Contract Number:: AC05-00OR22725

OSTI ID:: 1546555

Alternate ID(s):: OSTI ID: 1642290

Journal Information:: Additive Manufacturing, Vol. 28, Issue C; ISSN 2214-8604

Publisher:: ElsevierCopyright Statement

Country of Publication:: United States

Language:: English

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Cited by: 23 works

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References (14)

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Correlations Between Powder Feedstock Quality, In Situ Porosity Detection, and Fatigue Behavior of Ti-6Al-4V Fabricated by Powder Bed Electron Beam Melting: A Step Towards Qualification Nandwana, Peeyush; Kirka, Michael M.; Paquit, Vincent C. JOM, Vol. 70, Issue 9 https://doi.org/10.1007/s11837-018-3034-6	journal	July 2018
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In Operando Monitoring by Analysis of Backscattered Electrons during Electron Beam Melting Arnold, Christopher; Böhm, Jonas; Körner, Carolin Advanced Engineering Materials, Vol. 22, Issue 9 https://doi.org/10.1002/adem.201901102	journal	December 2019

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42 ENGINEERING
36 MATERIALS SCIENCE
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Qualification
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Title: Approach to qualification using E-PBF in-situ process monitoring in Ti-6Al-4V

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