Additive Manufacturing: Equipment, Instrumentation and In-Situ Process Monitoring: Standards in Additive Manufacturing Materials
Sponsored by: TMS Additive Manufacturing Committee
Program Organizers: Ulf Ackelid, Freemelt AB; Joy Gockel, Colorado School Of Mines; Sneha Prabha Narra, Carnegie Mellon University; Ola Harrysson, North Carolina State University
Monday 2:00 PM
October 10, 2022
Room: 304
Location: David L. Lawrence Convention Center
Session Chair: Mark Stoudt, National Institute of Standards and Technology; Paul Mason, Thermo-Calc Software Inc.
2:00 PM Invited
Additive Manufacturing Standardization Landscape and Recent Initiatives Advancing Standards Development: Richard Huff1; Mahdi Jamshidinia1; Mohsen Seifi1; 1ASTM International
This presentation will provide a foundational understanding of the role and types of standards relied on for confidence in the design, production and use of critical parts produced by Additive Manufacturing (AM). A review of the current landscape of AM standards is provided and examples of recent developments which are key to supporting continued adoption of AM technologies are discussed. This talk will also introduce the ASTM International Additive Manufacturing Center of Excellence (AM CoE) and the “Research to Standards” initiative focused on accelerating standards development. This talk will highlight the role the materials research community can play in advancing standardization and adoption of new AM technologies.
2:20 PM Invited
Scientific Foundations and Approaches for Qualification of Additively Manufactured Structural Components: Sharlotte Kramer1; Tyler LeBrun1; Jonathan Pegues1; 1Sandia National Laboratories
Additive manufacturing (AM) maintains a wide process window that enables complex designs otherwise unattainable via conventional production technologies. However, the lack of confidence in qualifying AM parts that leverage AM process-structure-property-performance (PSPP) relationships stymies design optimization and adoption of AM. While continuing efforts to map fundamental PSPP relationships that cover the potential design space, we first need pragmatic and then long-term solutions that overcome challenges associated with qualifying AM-designed parts. Two pragmatic solutions include: 1) AM material specifications to substantiate process reproducibility and 2) component risk categorization to associate system risk relative to part performance and required part quality. A novel qualification paradigm under development involves efficient prediction of part performance over wide-ranging PSPP relationships through targeted testing and computational simulation. This talk describes Sandia projects on PSPP relationship discovery, these pragmatic approaches, and the novel qualification approach. SNL is managed and operated by NTESS under DOE NNSA contract DE-NA0003525.
2:40 PM Invited
Providing a Rigorous Benchmark Measurement Foundation for Modeling-Informed Qualification and Certification of Metal AM Components: Lyle Levine1; Brandon Lane1; 1National Institute of Standards and Technology
Additive manufacturing (AM) is a transformative technology that enables customized production of parts with geometries that can be too costly, difficult, or in some cases, impossible to produce using traditional manufacturing processes. However, difficulties persist regarding throughput, reproducibility, reliability, and properties of the printed parts. Quantitative modeling is critical for mitigating these problems, but broad model validation requires community access to extensive benchmark test data. I will describe the Additive Manufacturing Benchmark Series (AM Bench) which provides rigorous measurement test data for validating AM simulations for a broad range of AM technologies and material systems. Through a collaboration encompassing nearly a hundred scientists from 11 NIST divisions and 19 external organizations, in 2022 AM Bench released nine large sets of metal and polymer AM benchmark data. Here, I will describe the AM Bench measurements and discuss how they fit into the context of qualification and certification of AM components.
3:00 PM Invited
Role of Interstitial Alloying Elements on Microstructural Evolution in Additively Manufactured Materials: Todd Palmer1; 1Pennsylvania State University
Metal powders are a prominent feedstock used for fusion-based additive manufacturing processes and are produced within the same compositional limits as their wrought counterparts. However, small additions of interstitial alloying elements, which are not typically monitored, can impact the microstructural evolution during both additive manufacturing and post-process heat treatments. For example, high oxygen levels in stainless steels drive the formation of oxygen-rich inclusions that impact microstructural formation, mechanical properties, and corrosion behavior. Solid solution strengthened nickel base alloys were influenced by high nitrogen levels that drove the formation of nitride-based phases in the as deposited condition and persist through post-processing. Emerging computational tools are being combined with in situ and ex situ high resolution characterization techniques to identify these phases and build databases for predicting microstructural evolution and material properties and performance.
3:20 PM Invited
New Standardization Efforts to Collect, Correlate, and Identify Metrics of Reuse Powder with Functional Performance Data of Material Resultant of Additive Manufacturing Workflows: Tyler Lebrun1; 1Sandia National Laboratories
Best practices for using metal powder feedstocks in additive manufacturing have relied upon establishing conformance to powder specifications. Similarly, industry process specifications have been established to help control for reproducible production of new metal powder feedstocks, but not until recently has a similar document been released to control the processes to prepare recovered used powder for reuse. However, the size scale at which powder requirements are measured and evaluated cannot distinguish between potentially non-conforming, deleterious particles that persist since the first build cycle a powder lot. Therefore, a stopgap powder history scoring metric and labeling schema is currently proposed to both track and associate powder history with user-supplied performance data, guiding the creation of application-specific powder end-of-life determination. An organization may institute a risk assessment posture that relies on this correlated material property data with powder history scoring criteria to identify feedstocks robust to produce parts that meet requirements.
3:40 PM Break
4:00 PM Invited
AM Materials Data – Challenges and Opportunities: Richard Huff1; 1ASTM International
While AM continues to experience steady growth, as a percentage of the total manufacturing economy, AM is still a niche process. A few of the main impediments to greater adoption remain the high capital equipment cost, the maturity of AM systems for reliable and repeatable production, and the availability of materials data. Even when available, the pedigree is often too low to utilize and trust the data. The ASTM Industry Consortium initiative is to bringing companies together from across the entire AM value stream to collaborate on standardizing the requirements and best practices for AM material data generation and creating and managing shared high-pedigree “reference” datasets. Opportunities created from standardized high-pedigree materials data for developing the tools needed to support rapid process optimization, qualification of new AM applications, materials and technologies, and real-time quality assurance needed to scale AM production are discussed.
4:20 PM Invited
Additive Materials Data: Truths and Myths: Amber Andreaco1; Mark Shaw1; 1GE Additive
For decades, metallic materials data has been collected across various processing methods such as casting and forging. As additive manufacturing (AM) enters the arena as another way to make metal, the data collection process is being conducted at a grand scale across modalities, OEMs, parameter sets, post-processing techniques, etc… Strategic data collection and analysis is and will continue to be crucial for rapid adoption of AM within various industries. This talk will cover the commonly debated topics with regards to materials data including what constitutes a thorough collection of AM material pedigree, how to leverage parallel approaches to traditional manufacturing, and why rigorously defining materials standards is important.
4:40 PM Invited
An Intelligent Data Infrastructure for Additive Manufacturing: Shengyen Li1; 1Southwest Research Institute
Additive manufacturing (AM) is a sophisticated technology requiring a large set of parameters for laser building and post processing to achieve the objective material performance. This presentation will demonstrate a pilot project with America Makes in which an intelligent data infrastructure is developed to archive, search, share, and reuse AM data in an automated fashion. A pedigree XML-based database accommodates the data including the project background, feedstock information, AM and post-building schedules, microstructure characterization, property measurements, and simulation codes. This infrastructure contains a Python tool to parse, cure, upload, and share data. To reduce the manual efforts for data entry, this tool integrates with a natural language processing tool for capturing the key words and project features in an ontology map for data mining. This presentation will also demonstrate the gaps between data and data models. Case Number AFRL-2022-1546 was assigned a clearance of CLEARED on 31 Mar 2022.
5:00 PM Invited
Research and Standards Development Needs for AM Industrialization: Brandon Ribic1; 1America Makes
Driven by the National Center for Defense Manufacturing and Machining (NCDMM), America Makes is a Department of Defense Manufacturing Innovation Institute focused on additive manufacturing (AM) technologies. Since its inception, America Makes has leveraged a national collaborative ecosystem to advance the readiness level of AM technologies and invigorate the knowledge base, skills, and training available for the domestic AM supply chain. Our strategy is the product of collaboration with our membership, which is comprised of representation from all tiers of the domestic AM supply chain. America Makes and the American National Standards Institute (ANSI) lead a partnership known as the AM Standardization Collaborative (AMSC) to coordinate and accelerate the development of industry-wide additive manufacturing (AM) standards and specifications. An introduction to America Makes, the AMSC, and a perspective outlining needs for research and standards for the industrialization of AM technologies will be presented.