Extreme‐Value Statistics Reveal Rare Failure‐Critical Defects in Additive Manufacturing
Additive manufacturing enables the rapid, cost effective production of customized structural components. To fully capitalize on the agility of additive manufacturing, it is necessary to develop complementary high‐throughput materials evaluation techniques. In this study, over 1000 nominally identica...
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| Published in | Advanced engineering materials Vol. 19; no. 8 |
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| Main Authors | , , , , , , |
| Format | Journal Article |
| Language | English |
| Published |
United States
Wiley
01.08.2017
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| Subjects | |
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| Abstract | Additive manufacturing enables the rapid, cost effective production of customized structural components. To fully capitalize on the agility of additive manufacturing, it is necessary to develop complementary high‐throughput materials evaluation techniques. In this study, over 1000 nominally identical tensile tests are used to explore the effect of process variability on the mechanical property distributions of a precipitation hardened stainless steel produced by a laser powder bed fusion process, also known as direct metal laser sintering or selective laser melting. With this large dataset, rare defects are revealed that affect only ≈2% of the population, stemming from a single build lot of material. The rare defects cause a substantial loss in ductility and are associated with an interconnected network of porosity. The adoption of streamlined test methods will be paramount to diagnosing and mitigating such dangerous anomalies in future structural components.
Arrays of tensile bars printed by laser powder bed fusion (additive manufacturing) are tested with a high‐throughput mechanical test method. The resulting property distributions reveal within‐ and between‐build variability as well as anomalous behavior associated with rare, failure‐critical defects. |
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| AbstractList | Additive manufacturing enables the rapid, cost effective production of large populations of material test coupons such as tensile bars. By adopting streamlined test methods including ‘drop-in’ grips and non-contact extensometry, testing these large populations becomes more efficient. Unlike hardness tests, the tensile test provides a direct measure of yield strength, flow properties, and ductility, which can be directly incorporated into solid mechanics simulations. In the present work, over 1000 nominally identical tensile tests were used to explore the effect of process variability on the mechanical property distributions of a precipitation hardened stainless steel, 17-4PH, produced by a laser powder bed fusion process, also known as direct metal laser sintering. With this large dataset, rare defects are revealed that affect only ~2% of the population, stemming from a single build lot of material. Lastly, the rare defects caused a substantial loss in ductility and were associated with an interconnected network of porosity. Additive manufacturing enables the rapid, cost effective production of customized structural components. To fully capitalize on the agility of additive manufacturing, it is necessary to develop complementary high‐throughput materials evaluation techniques. In this study, over 1000 nominally identical tensile tests are used to explore the effect of process variability on the mechanical property distributions of a precipitation hardened stainless steel produced by a laser powder bed fusion process, also known as direct metal laser sintering or selective laser melting. With this large dataset, rare defects are revealed that affect only ≈2% of the population, stemming from a single build lot of material. The rare defects cause a substantial loss in ductility and are associated with an interconnected network of porosity. The adoption of streamlined test methods will be paramount to diagnosing and mitigating such dangerous anomalies in future structural components. Arrays of tensile bars printed by laser powder bed fusion (additive manufacturing) are tested with a high‐throughput mechanical test method. The resulting property distributions reveal within‐ and between‐build variability as well as anomalous behavior associated with rare, failure‐critical defects. |
| Author | Madison, Jonathan D. Swiler, Laura P. Rodelas, Jeffrey M. Jared, Bradley H. Boyce, Brad L. Salzbrenner, Bradley C. Shen, Yu‐Lin |
| Author_xml | – sequence: 1 givenname: Brad L. surname: Boyce fullname: Boyce, Brad L. email: blboyce@sandia.gov organization: Sandia National Laboratories – sequence: 2 givenname: Bradley C. surname: Salzbrenner fullname: Salzbrenner, Bradley C. organization: Sandia National Laboratories – sequence: 3 givenname: Jeffrey M. surname: Rodelas fullname: Rodelas, Jeffrey M. organization: Sandia National Laboratories – sequence: 4 givenname: Laura P. surname: Swiler fullname: Swiler, Laura P. organization: Sandia National Laboratories – sequence: 5 givenname: Jonathan D. surname: Madison fullname: Madison, Jonathan D. organization: Sandia National Laboratories – sequence: 6 givenname: Bradley H. surname: Jared fullname: Jared, Bradley H. organization: Sandia National Laboratories – sequence: 7 givenname: Yu‐Lin surname: Shen fullname: Shen, Yu‐Lin organization: University of New Mexico |
| BackLink | https://www.osti.gov/servlets/purl/1343622$$D View this record in Osti.gov |
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| Snippet | Additive manufacturing enables the rapid, cost effective production of customized structural components. To fully capitalize on the agility of additive... Additive manufacturing enables the rapid, cost effective production of large populations of material test coupons such as tensile bars. By adopting streamlined... |
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| SubjectTerms | additive manufacturing deformation MATERIALS SCIENCE power bed fusion statistics tensile |
| Title | Extreme‐Value Statistics Reveal Rare Failure‐Critical Defects in Additive Manufacturing |
| URI | https://onlinelibrary.wiley.com/doi/abs/10.1002%2Fadem.201700102 https://www.osti.gov/servlets/purl/1343622 |
| Volume | 19 |
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