Additive Manufacturing: Advanced Characterization with Synchrotron, Neutron, and In Situ Laboratory-scale Techniques: Industrial Applications and Perspectives
Sponsored by: TMS: Additive Manufacturing Committee
Program Organizers: Fan Zhang, National Institute of Standards and Technology; Tom Stockman, Los Alamos National Laboratory; Tao Sun, Northwestern University; Donald Brown, Los Alamos National Laboratory; Yan Gao, Ge Research; Amit Pandey, Lockheed Martin Space; Joy Gockel, Wright State University; Tim Horn, North Carolina State University; Sneha Prabha Narra, Carnegie Mellon University; Judy Schneider, University of Alabama at Huntsville
Wednesday 8:30 AM
February 26, 2020
Room: 8
Location: San Diego Convention Ctr
Session Chair: Yan Gao, GE Global Research; Amit Pandey, ANSYS
8:30 AM Invited
In-situ X-ray, IR, and Diffraction Measurements of Automotive Grade Steel During Laser Powder Bed Fusion: Andrew Bobel1; Louis Hector1; Benjamin Gould2; Sarah Wolff2; 1General Motors; 2Argonne National Laboratory
The effects of laser process parameters on melt pool and vapor cavity dynamics, thermal evolution, and transient phase transformations in additively manufactured automotive grade steels was studied. The dynamic melting process of commonly used automotive grade 4140 steel was examined using high-speed X-ray imaging concurrently with high-resolution thermal IR imaging. The laser energy and scan speed using continuous wave laser mode were explored. The thermal profiles of the additively built material were then correlated with analogous high-speed in-situ diffraction studies to extract the transient phase transformations characteristic to this low alloy steel during the rapid melt and solidification cycles accompanying the additive manufacturing process. These results will provide an accurate mathematical expression of laser heat source (e.g. Goldak’s double-ellipsoid heat source) for a finite element based model. The model will be utilized to develop automotive grade materials and process parameters/strategies with minimal defects and higher process throughput.
8:55 AM Invited
Practical Use of Neutron Facility VULCAN and NRSF2 for Residual Stress Analysis of Additive Manufactured Large Automobile Parts: Tomohiro Ikeda1; Satoshi Hirose1; Hisao Uozumi1; Ke An2; Chen Yan2; Andrew Payzant2; Jeffrey Bunn2; Christopher Fancher2; Alan Seid3; 1Honda R&D Co., Ltd.; 2Oak Ridge National Laboratory; 3Honda R&D Americas Inc.
Metal additive manufacturing has great potential to produce higher functional parts, due to their high shape flexibility and unique material properties. On the other hand, residual stress which is generated by rapid solidification causes deformation, cracks and failure under building process. To avoid these problems, understanding of internal residual stress distribution is one of the effective way. In this presentation, Honda’s approach toward understanding internal residual stress by neutron which has a high penetration depth will be introduced. Also, stress distribution in the aluminum cylinder head, comparison with simulation results and future outlook to improve simulation technique will be presented.
9:20 AM Invited
In Operando Characterization of 3D Printed Composite Resins via X-ray Photon Correlation Spectroscopy and SAXS: Hilmar Koerner1; 1Air Force Research Laboratory
Creating more robust additive manufacturing routes for Air Force applications requires a detailed physics-based understanding of the process. The effects of printing parameters, environment and interplay between constituents during an extrusion-based process that creates complex shaped parts are crucial to the performance that can be achieved via additive manufacturing. Mapping both dynamics and morphology in real time is essential to understand the limitations of the process and to eliminate key bottlenecks. We use X-ray Photon Correlation Spectroscopy to capture fast processes and the shear induced morphological evolution of polymer and fillers during Direct Write and Fused Filament Fabrication of polymer matrix composites. The findings of these experiments may lead to the redesign of nozzle geometries and surfaces to obtain improved road to road bonding.
9:45 AM
4D Nanoscale Imaging of Powder Feedstock Processing for Additive Manufacturing: Stephen Kelly1; Kyle Tsaknopoulos2; Jordan Kone1; Danielle Cote2; Hrishi Bale3; 1Carl Zeiss X-ray Microscopy; 2Worcester Polytechnic Institute; 3Carl Zeiss Microscopy Inc.
The flexibility of additive manufacturing brings new opportunities for fabricating parts with structures and properties not possible through traditional subtractive processes. In additive manufacturing, each process along the path from powder to part must be optimized to ensure ultimate success. Tailoring the powder microstructure via, e.g. annealing, can change how that powder operates in a manufacturing process. We present here results from examining microstructural changes in a single Al 6061 particle caused by annealing. By leveraging the non-destructive nature of laboratory nanoscale x-ray microscopy, we imaged the internal microstructure of a single (~40 µm) powder particle in 3D at resolutions down to 50 nm. Tomographic analysis of the particle before and after a heat treatment reveals distinct microstructural changes caused by the annealing, including an increase in secondary phase size. We will discuss the implications of this analysis towards powder performance in a cold-spray manufacturing process.
10:05 AM Break
10:25 AM Panel Discussion We would like to use this opportunity to discuss research priorities that matter the most to manufacturing industry. Recognizing most researchers at universities and national labs are not well connected with industry and additive manufacturing is a manufacturing process, it is important to have such a discussion so that we can better align the research directions with current and future industrial needs. Emphasis will be given to advanced characterization and the best use of synchrotron and neutron techniques. The panelists are experts from industry, national labs and university, including Thomas Broderick (AFRL), Ed Glaessgen (NASA), Lyle Levine (NIST), Ade Makinde (GE), and Tony Rollett (CMU).