期刊
JOURNAL OF MATERIALS PROCESSING TECHNOLOGY
卷 311, 期 -, 页码 -出版社
ELSEVIER SCIENCE SA
DOI: 10.1016/j.jmatprotec.2022.117775
关键词
Laser powder bed fusion; Additive manufacturing; Ti-6Al-4V; Process window; Defects; Fatigue; Qualification
This manuscript provides a compact overview of the results that demonstrate the applicability of processing-structure-property relationships in 3D printing of metals. The proposed process qualification approach based on physics-based understanding of defect formation shows promise in enabling certification for aerospace-grade titanium alloy. It is expected to be applicable to other materials and powder bed fusion AM technologies.
The aim of this manuscript is to give a compact overview of the results that illustrate the applicability of processing-structure-property relationships in the increasingly important context of 3D printing of metals. A process qualification approach based on the physics-based understanding of defect formation in laser powder bed fusion (L-PBF) additive manufacturing (AM) is investigated for an aerospace-grade titanium alloy (Ti-6Al-4V). A physically interpretable qualification approach is critical for enabling L-PBF part certification for structure -critical applications. This approach relies on systematic experimentation, characterization, testing, and data analysis tasks including design of experiments varying power and velocity to generate varying defect pop-ulations, process window development based on defect structure, high throughput fatigue testing, and fractog-raphy, 2D porosity characterization, and use of extreme value statistics to develop a porosity metric that, in turn, could have predictive power for the variation in fatigue performance. Results from four-point bend fatigue tests demonstrate that a process window can be defined based on this key mechanical property. This relatively high throughput approach can, in turn, support a reduced set of round bar fatigue tests typically used for qualification. Overall, the proposed ecosystem for process qualification of L-PBF AM shows promise and is expected to apply to other materials and powder bed fusion AM technologies.
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