Additive Manufacturing Benchmarks 2022 (AM-Bench 2022): Alternate AM Methods and Materials I
Program Organizers: Brandon Lane, National Institute of Standards and Technology; Lyle Levine, National Institute of Standards and Technology
Monday 3:30 PM
August 15, 2022
Room: Cabinet/Judiciary Suite
Location: Hyatt Regency Bethesda
Session Chair: Allison Beese, Pennsylvania State University
3:30 PM Invited
Multiscale Material Modeling of Laser Powder Bed Fusion Additive Manufacturing Soft Magnetic Composites: Li Ma1; Caleb Andrew2; Ryan Carter1; Mitra Taheri2; Joe Sopcisak1; 1Johns Hopkins University Applied Physics Laboratory; 2Johns Hopkins University
Soft magnetic composites (SMCs), which provide high electrical resistivity with high magnetic permeability, have the potential to create lighter and more efficient electronic devices. With the increasing complexity of these devices, conventional manufacturing methods limited their application. Recent advances in multi-material Laser Powder Bed Fusion (L-PBF) Additive Manufacturing (AM) have enabled the production of more complex SMCs. Our prior research has demonstrated that the as-built L-PBF sample with multi-material system incorporating NiZnCu-ferrite and high purity iron showed high maximum relative permeability. However, it is challenge to produce fully dense SMCs without defects. To improve the magnetic properties and reduce defects within the multi-material system, we develop the multiscale material modeling of L-PBF NiZnCu-ferrite soft magnetic composites. Mean field homogenization method is applied for two material system. The effect of various composition and scanning parameters on the melting pool size is studied. The computational results are compared with L-PBF experimental results.
4:00 PM
Linkage of Microstructural Features and Mechanical Properties of BinderJet Fabricated 316 Stainless Steel Through Ultrasound Measurements: Nancy Huang1; Olivia Cook1; Robert Smithson2; Christopher Kube1; Andrea Argüelles1; Allison Beese1; 1Pennsylvania State University; 23M Company
Binder jet additively manufactured stainless steel 316L (SS316L) and stainless steel 316 infiltrated with bronze (SS316+bronze) samples were characterized through ultrasonic testing, microscopy, and mechanical testing. Ultrasonic attenuation increased, and wave speed decreased, with increased porosity, and wave speed was positively correlated to grain size. Interconnected pores and larger grains were present near the center of the SS316L sample, compared to the isolated pores and smaller grains near the SS316L sample surfaces, leading to competing influences in the measured wave speed. Samples machined from the SS316L and SS316+bronze had decreasing ultimate tensile strength and ductility with increased grain size and porosity, as indicated by an increase in both the attenuation and the standard deviation of wave speed. This presentation will demonstrate the application of ultrasonic testing to detect variations in microstructure and mechanical properties in metal alloys made via binder jetting.
4:20 PM
Porosity Characterization of BinderJet Additive Manufacturing Parts via Ultrasonic Methods: Olivia Cook1; Nancy Huang1; Robert Smithson2; Christopher Kube1; Allison Beese1; Andrea Argüelles1; 1Pennsylvania State University; 23M Company
Binder jet metallic additive manufacturing (AM) is a popular alternative to fusion-based metal AM processes. However, binder jetting is prone to porosity, which decreases the adoption of binder jetted parts. To bring insight to the binder jet process, ultrasonic testing is applied to generate spatially dependent ultrasonic wave speed and attenuation measurements and help characterize and map porosity. Ultrasonic testing was conducted in an immersion system on binder jetted stainless steel and stainless steel infiltrated with bronze. X-ray computed tomography was performed to provide a ground truth assessment of porosity. Maps of wave speed and attenuation displayed a strong correlation to the X-ray CT pore reconstructions. As expected, the ultrasonic wave speed and attenuation were found to be sensitive to average pore size and volume fraction. This work supports the utility of using ultrasonic testing to help develop and improve the binder jet AM process and corresponding parts.