Additive Manufacturing Benchmarks 2022 (AM-Bench 2022): Wednesday Benchmarks
Program Organizers: Brandon Lane, National Institute of Standards and Technology; Lyle Levine, National Institute of Standards and Technology
Wednesday 10:20 AM
August 17, 2022
Room: Regency Ballroom I & II
Location: Hyatt Regency Bethesda
Session Chair: Jian Cao, Northwestern University
10:20 AM Plenary
3-Dimensional Microstructure Characterization of Laser Powder Bed Fusion IN625 and IN718: Edwin Schwalbach1; Michael Chapman2; Megna Shah2; Michael Uchic2; Lyle Levine3; Nik Hrabe3; Orion Kafka3; Newell Moser3; James Belak4; 1Air Force Research Labroatory; 2Air Force Research Laboratory; 3National Institute of Standards and Technology; 4Lawrence Livermore National Laboratory
Laser Powder Bed Fusion processing can produce complex microstructures which vary spatially, both within a build layer, as well as from layer to layer. Experimental characterization of as-built material produced as part of AM-Bench was executed to quantify such microstructures and ultimately inform microstructure modeling efforts. Three-dimensional reconstructions spanning 500 µm × 500 µm × 1000 µm in IN625 and IN718 samples were generated using automated mechanical polishing serial sectioning. Optical microscopy, backscatter electron imaging, and electron back-scatter diffraction data were collected on approximately 500 sections from each sample. Data registration and fusion techniques were then utilized to combine these different data modes to provide detailed characterization of the as-printed surface, internal porosity, grain structure, and local crystallographic orientation.
10:50 AM Plenary
AM Bench 2022 -04 Overview of Mechanical Measurements on PBF-L Inconel 625: Nik Hrabe1; Robert Carson2; Darren Pagan3; Saadi Habib1; Jordan Weaver1; Jake Benzing1; Li-Anne Liew1; Newell Moser1; Orion Kafka1; Nicholas Derimow1; 1National Institute of Standards and Technology; 2Lawrence Livermore National Laboratory; 3Pennsylvania State University
An overview of all mechanical measurements from AM Bench 2022 as well as high-level results from the associated challenges will be presented in this talk. All measurements were performed on Inconel 625 fabricated on a commercial laser powder bed fusion (PBF-L) machine. Some of these measurements were performed on the exact specimens characterized in AM Bench 2018, and other measurements used new specimens built on the same machine. There were three mechanical measurements with associated challenges: (1) Subcontinuum Mesoscale Tensile Test [CHAL-AMB2022-04-MeTT], (2) Macroscale Tensile Tests at Different Orientations [CHAL-AMB2022-04-MaTO], and (3) Macroscale Compression at Different Temperatures and Orientations [CHAL-AMB2022-04-MaCTO]. There were two additional mechanical measurements that did not have associated challenges but are publicly available for the modeling community to use for model development, validation, and verification: (4) Macroscale Tensile Tests at Different Strain Rates and (5) Macroscale Compression Tests with In-Situ Diffraction at Different Temperatures and Strain Rates.
11:20 AM Plenary
Elastic Residual Strain Measurements of 3D Additive Manufacturing Builds of IN718 AM-Benchmark Artifact: An Overview and Comparison Between Measurement Techniques and Submitted Simulation Results: Thien Phan1; Mehmet Hazar Seren2; Thomas Gnaupel-Herold3; Michael Hill4; Nicholas Bachus5; Christopher D'Elia6; Kelly Nygren2; Darren Pagan7; J Peter Ko2; Lyle Levine3; 1Lawrence Livermore National Laboratory; 2Cornell High Energy Synchrotron Source; 3National Institute of Standards and Technology; 4Univ Of California Davis; 5University Of California Davis; 6University of California, Davis; 7Pennsylvania State University
The complexity of the laser powder bed fusion process makes it challenging to accurately predict the build success, part distortion, surface roughness, local microstructures, etc. Additionally, the high cost of materials and time further highlight the importance of accurate simulations. These AM simulations often rely on numerous assumptions and “tuning” of variables, and therefore, rigorous benchmark measurements are needed to validate such predictions. Here an overview of the residual strains and stresses of the 3D IN718 AM benchmark artifact measured using energy dispersive X-ray diffraction, neutron diffraction, and contour method will be presented. Submitted elastic strain simulation results will also be compared to energy dispersive X-ray diffraction measurements.
11:50 AM Question and Answer Period