Additive Manufacturing Benchmarks 2022 (AM-Bench 2022): Poster & Exhibitor Session
Program Organizers: Brandon Lane, National Institute of Standards and Technology; Lyle Levine, National Institute of Standards and Technology
Monday 5:00 PM
August 15, 2022
Room: Regency Ballroom Foyer
Location: Hyatt Regency Bethesda
Non-destructive, Low-cost Qualification of AM Material and Processes Using RF Measurements: Nandagopal Matavalam1; Paul Carriere1; Pedro Frigola1; Sergey Kutsaev1; Alexander Smirnov1; Aurora Araujo1; 1Radiabeam Technologies
Characterization and quality control of a given AM material and process has been of interest over the past decade. Although parts with complex geometries can be easily printed, characterizing internal features is often difficult and/or expensive. This problem is often solved by incorporating external witness features on the part as well as separate parts in the build such as tensile specimens. In this presentation, we will present ongoing efforts to qualify the finish and geometric accuracy of a given material, machine and post-process using a low-cost RF test specimen. Our non-destructive measurement provides information regarding the geometry and finish of inaccessible internal features and can be repeated throughout the manufacturing sequence. We will discuss how this method has been applied to various materials (copper, niobium, aluminum, titanium); processes (SLA, EB-PBF, L-PBF) and finishing methods (abrasive, chemical, electropolishing). Strategies to scale this approach for end-to-end quality control will also be discussed.
Experimental Evaluation of Mechanical Properties of Additively Manufactured 17-4 PH Stainless Steel: Bijit Kalita1; Gaurav Singh1; Jayaganthan R.1; 1Indian Institute of Technology Madras
Additive manufacturing (AM) is a novel manufacturing method which provides more freedom in design, manufacturing near net shaped parts as per demand. Among various AM techniques, Laser Powder Bed Fusion (L-PBF) is the most prominent one that provides higher accuracy and powder proficiency in comparison to other methods. Additively manufactured 17-4 PH stainless steel exhibited a dendritic solidification microstructure in the as-built condition. It is widely used as a structural material in marine, aerospace and chemical industries. This study provides an insight into the comparison of the tensile properties between 17-4 PH SS samples processed by L-PBF and wrought 17-4 PH samples. The tests were conducted according to the international standard ASTM E8 and the microstructural studies were also performed. The L-PBF built part revealed superior tensile properties against the wrought sample. Furthermore, the L-PBF processed sample displayed significantly higher ductility and ultimate tensile strength with respect to wrought samples.
Powder Blown Laser DED Sensor Development for
Mass Flow Monitoring and Defect Detection: Zachary Brunson1; Aaron Stebner1; 1Georgia Institute of Technology
Process monitoring is essential for process repeatability and qualification, and for AM components can serve to help qualify the final parts themselves. For powder blown laser DED, mass flow is a crucial parameter whose measurement has proven to be particularly difficult, often with large errors. Similarly, current research approaches for defect detection in AM parts using optical, thermal, and acoustic monitoring have shown promise, but tend to be limited to qualitative assessments rather than quantitative ones. With these challenges in mind, we are working to develop a 3-mechanism sensing approach using coupled acoustic, capacitive, and inductive techniques with the goal of reducing mass flow measurement errors and eventually measuring the composition of mixed powder flows. We are also developing a magnetic computed tomography system for in-situ quantification of defects and their layer-by-layer evolution, including formation, migration, and annihilation. These sensors are also part of a greater DED process monitoring investigation.