Additive Manufacturing Benchmarks 2022 (AM-Bench 2022): Mechanical Behavior II
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: Regency Ballroom I & II
Location: Hyatt Regency Bethesda
Session Chair: Nicholas Derimow, National Institute of Standards and Technology
3:30 PM Invited
Fast and Effective Sensitivity and Uncertainty Quantification for Metal-based Additive Manufacturing: David Restrepo1; Juan Sebastian Rincon Tabares1; Matthew Balcer1; Mauricio Aristizabal1; Arturo Montoya1; Harry Millwater2; 1The University of Texas at San Antonio; 2University of Texas at San Antonio
Two novel technologies are presented in support of Qualification and Certification process for AM. The first technology corresponds to the hypercomplex finite element method that allows one to calculate highly-accurate arbitrary-order sensitivities of thermal and material responses with respect to initial conditions, loadings, material properties, or shape. This technology allows one to quantify the relative importance of the build parameters. Moreover, these sensitivities provide the basis for a fast uncertainty quantification (UQ) method that uses a Taylor series expansion to approximate the probability of distributions of any output. As a result, one can utilize all the full fidelity of a finite element model and obtain UQ information without the need on relying on Monte Carlo sampling of simplified or surrogate models, which limits accuracy, or relying on polynomial chaos or design of experiment approaches that limit the number of parameters considered.
4:00 PM
Elimination of Solidification Cracking in AA 6061 Alloy During the Laser Powder Bed Fusion Additive Manufacturing Process: Sivaji Karna1; Rimah Al-Aridi1; Tianyu Zhang1; Timothy Krentz2; Dale Hitchcock2; Andrew Gross1; Lang Yuan1; 1University of South Carolina; 2Savannah River National Lab
AA 6061 is a high-strength heat treatable aluminum alloy used in various applications such as aerospace and automotive industries. Solidification cracking is one of the dominant defects in the printing of AA 6061 alloy via laser powder bed fusion (L-PBF) additive manufacturing. In this study, AA 6061 cubes were printed with a range of laser power, scanning speed, hatch spacing, and substrate temperature to establish the correlation between the process parameters and the solidification cracking behaviors. In parallel, a L-PBF process model of the melt pool formation was coupled with solidification cracking criteria to interpret the experimental observations and assist the experimental design in eliminating solidification cracks. Tensile samples with selected process parameters resulting in different levels of solidification cracking were printed to investigate their mechanical properties and failure mechanisms. Finally, the process window for crack-free AA6061 and the anticipated mechanical properties are proposed.
4:20 PM
(On-Demand) A Study on Tensile and Fracture Behaviour of Al 2024 – Ram 2 Alloy Fabricated Through Laser Powder Bed Fusion.: Saurabh Gairola1; R. Jayaganthan1; 1Indian institute of technology Madras
The microstructure and mechanical properties such as tensile and fracture behaviour of Al 2024 – Ram 2 alloy fabricated through laser powder bed fusion is investigated in this study. Ram 2 alloy was produced by 2 % ceramic addition in Al 2024 matrix. Most of the studies in additive manufacturing of aluminium alloys are currently focused on Al-Si alloys like AlSi10Mg, AlSi12 and literature on LPBF of high strength aluminium alloys is limited. Al 2024 is one of the most widely used alloys for aerospace and automobile applications. Al 2xxx series alloys are difficult to process by additive manufacturing due to solidification-related issues resulting from the thermomechanical cycles during AM processes. To obviate these issues, optimized process parameters were used to fabricate defect-free and dense Ram 2 coupons. Test specimen were printed at longitudinal and transverse orientations. The microstructural characterization of printed samples was extensively performed using TEM, and XRD.
4:40 PM Invited
A Combined Experimental and Simulation Campaign of As-built AM IN625 Connecting Microstructure to Part Scale Response: Robert Carson1; James Belak1; Matthew Rolchigo2; Leonidas Zisis3; Michael Sangid3; Darren Pagan4; 1Lawrence Livermore National Laboratory; 2Oak Ridge National Laboratory; 3Purdue University; 4Pennsylvania State University
The Exascale Additive Manufacturing (ExaAM) project is developing a number of high-fidelity simulation capabilities and workflows for AM metals that goes from the melt pool physics all the way up to part scale response. The aim of the ExaAM project is to provide predictive simulation results that can guide the AM design process and help accelerate part qualifications. One of the goals of the project is to connect simulated microstructures to part scale simulations through the use of crystal plasticity (CP) simulations. Validation of both these microstructure and CP simulations required a number of experimental campaigns which made use of the NIST IN625 AMB2018-01 part build. This talk will be an overview of the experimental campaigns as well as the parameterization efforts of the crystal plasticity simulations using this gathered data.