Journal
COMPUTATIONAL MECHANICS
Volume 61, Issue 5, Pages 575-580Publisher
SPRINGER
DOI: 10.1007/s00466-017-1531-z
Keywords
Stress concentrations; Surface topology; Micromechanical modeling; Additive manufacturing; Synchrotron tomography
Funding
- NextManufacturing Center at CMU
- AFOSR [FA9550-16-1-0105]
- User Productivity Enhancement, Technology Transfer, and Training (PETTT) Program under the High Performance Computing Modernization Program (HPCMP)
- DOE Office of Science [DE-AC02-06CH11357]
- Office of Science of the U.S. Department of Energy [DE-AC02-05CH11231]
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Characterizing complex surface topologies is necessary to understand stress concentrations created by rough surfaces, particularly those made via laser power-bed additive manufacturing (AM). Synchrotron-based X-ray microtomography (PACT) of AM surfaces was shown to provide high resolution detail of surface features and near-surface porosity. Using the CT reconstructions to instantiate a micromechanical model indicated that surface notches and near-surface porosity both act as stress concentrators, while adhered powder carried little to no load. Differences in powder size distribution had no direct effect on the relevant surface features, nor on stress concentrations. Conventional measurements of surface roughness, which are highly influenced by adhered powder, are therefore unlikely to contain the information relevant to damage accumulation and crack initiation.
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