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The printability of artificial defects inside the additively manufactured laser powder bed fusion (LPBF) 316L stainless steel is investigated.
The printing parameters of the LPBF process are optimized to produce artificial defects with reproducible sizes at desired positions while minimizing redundant porosity. The smallest obtained artificial defect is 90 mu m in diameter.
The accuracy of the geometry of the printed defect depends on both the height and the diameter in the input model.
The effect of artificial defects on the very-high-cycle fatigue (VHCF) behavior of LPBF 316L stainless steel is also studied. The specimens printed with artificial defects in the center are tested under VHCF using an ultrasonic machine.
Crack initiation is accompanied by the formation of a fine granular area (FGA), typical of VHCF. Despite the presence of relatively large artificial defects, FGA formation is observed around accidental natural printing defects closer to the surface, which can still be considered as internal. The causes for this occurrence are discussed.
Additive manufacturing (AM) of metals and in particular laser powder bed fusion (LPBF) enables a degree of freedom in design unparalleled by conventional subtractive methods. To ensure that the designed precision is matched by the produced LPBF parts, a full understanding of the interaction between the laser and the feedstock powder is needed. It has been shown that the laser also melts subjacent layers of material underneath. This effect plays a key role when designing small cavities or overhanging structures, because, in these cases, the material underneath is feed-stock powder. In this study, we quantify the extension of the melt pool during laser illumination of powder layers and the defect spatial distribution in a cylindrical specimen. During the LPBF process, several layers were intentionally not exposed to the laser beam at various locations, while the build process was monitored by thermography and optical tomography. The cylinder was finally scanned by X-ray computed tomography (XCT). To correlate the positions of the unmolten layers in the part, a staircase was manufactured around the cylinder for easier registration. The results show that healing among layers occurs if a scan strategy is applied, where the orientation of the hatches is changed for each subsequent layer. They also show that small pores and surface roughness of solidified material below a thick layer of unmolten material (>200 mu m) serve as seeding points for larger voids. The orientation of the first two layers fully exposed after a thick layer of unmolten powder shapes the orientation of these voids, created by a lack of fusion.
The residual stress distribution in IN718 elongated prisms produced by selective laser melting was studied by means of neutron (bulk) and laboratory X-ray (surface) diffraction. Two deposition hatch lengths were considered. A horizontal plane near the top surface (perpendicular to the building direction) and a vertical plane near the lateral surface (parallel to the building direction) were investigated. Samples both in as-built (AB) condition and removed from the base plate (RE) were characterized. While surface stress fields seem constant for the AB condition, X-ray diffraction shows stress gradients along the hatch direction in the RE condition. The stress profiles correlate with the distortion maps obtained by tactile probe measurements. Neutron diffraction shows bulk stress gradients for all principal components along the main sample directions. We correlate the observed stress patterns with the hatch length, i.e., with its effect on temperature gradients and heat flow. The bulk stress gradients partially disappear after removal from the base plate.
This study examines the relationship between the magnetic mesostructure with the microstructure of low carbon steel tungsten inert gas welds. Optical microscopy revealed variation in the microstructure of the parent material, in the heat affected and fusion zones, correlating with distinctive changes in the local magnetic stray fields measured with high spatial resolution giant magneto resistance sensors. In the vicinity of the heat affected zone high residual stresses were found using neutron diffraction. Notably, the gradients of von Mises stress and triaxial magnetic stray field modulus follow the same tendency transverse to the weld. In contrast, micro-X-ray fluorescence characterization indicated that local changes in element composition had no independent effect on magnetic stray fields.
The use of post-processing heat treatments is often considered a necessary approach to relax high-magnitude residual stresses (RS) formed during the layerwise additive manufacturing laser powder bed fusion (LPBF). In this work, three heat treatment strategies using temperatures of 450 degrees C, 800 degrees C, and 900 degrees C are applied to austenitic stainless steel 316L samples manufactured by LPBF. These temperatures encompass the suggested lower and upper bounds of heat treatment temperatures of conventionally processed 316L. The relaxation of the RS is characterized by neutron diffraction (ND), and the associated changes of the microstructure are analyzed using electron backscattered diffraction (EBSD) and scanning electron microscopy (SEM). The lower bound heat treatment variant of 450 degrees C for 4 hours exhibited high tensile and compressive RS. When applying subsequent heat treatments, we show that stress gradients are still observed after applying 800 degrees C for 1 hour but almost completely vanish when applying 900 degrees C for 1 hour. The observed near complete relaxation of the RS appears to be closely related to the evolution of the characteristic subgrain solidification cellular microstructure.
The control of residual stress (RS) remains a challenge in the manufacturing of metallic parts using the laser powder bed fusion process (LPBF). This layer-by-layer manufacturing approach gives rise to complex triaxial RS distributions, which require extensive characterization effort for a broader acceptance of LPBF in industry. This study focuses on the distribution of bulk triaxial RS and surface RS in LPBF austenitic steel 316L. The RS are determined by X-ray and neutron diffraction to characterize the RS distribution. Variations in the LPBF parameters interlayer time (ILT) and scanning velocity and their influence on the temperature distribution and resulting RS is investigated using thermographic data from in situ process monitoring. The RS in the LPBF 316L is tensile at the surface and compressive in the bulk. The RS is directly related to the thermal history of the part as shown by the in situ thermography data. Shorter ILT leads to higher temperatures of the part during the manufacturing, which decrease the RS and RS formation mechanisms. Interestingly, the surface RS does not agree with this observation. This study highlights the benefit of using multiple RS determination methods and in situ thermography monitoring to characterize the RS in LPBF processed parts.
Talbot-Lau interferometry provides X-ray imaging techniques with significant enhancement of the radiographic contrast of weakly absorbing objects. The grating based technique allows separation of absorption, refraction and small angle scattering effects. The different efficiency of rectangular and triangular shaped phase gratings at varying detector distances is investigated. The interference patterns (Talbot carpets) are modeled for parallel monochromatic radiation and measured by synchrotron radiation. In comparison to rectangular shapes of phase gratings much higher visibility is obtained for triangular shapes which yield enhanced contrast of a glass capillary test specimen.
The performance of grating interferometers coming up now for imaging interfaces within materials depends on the efficiency (visibility) of their main component, namely the phase grating. Therefore, experiments with monochromatic synchrotron radiation and corresponding simulations are carried out. The visibility of a phase grating is optimized by different photon energies, varying detector to grating distances and continuous rotation of the phase grating about the grid lines. Such kind of rotation changes the projected grating shapes, and thereby the distribution profiles of phase shifts. This yields higher visibilities than derived from ideal rectangular shapes. By continuous grating rotation and variation of the propagation distance, we achieve 2D visibility maps. Such maps provide the visibility for a certain combination of grating orientation and detector position. Optimum visibilities occur at considerably smaller distances than in the standard setup.
The paper focuses on the reformulation of classic Maxwell's (1873) homogenization method for calculation of the residual stresses in matrix composites. For this goal, we equate the far fields produced by a set of inhomogeneities subjected to known eigenstrains and by a fictitious domain with unknown eigenstrain. The effect of interaction between the inhomogeneities is reduced to the calculation of the additional field acting on an inhomogeneity due to the eigenstrains in its neighbors. An explicit formula for residual stresses is derived for the general case of a multiphase composite. The method is illustrated by several examples. The results are compared with available experimental data as well as with predictions provided by the non-interaction approximation (Eshelby solution). It is shown that accounting for interaction can explain many experimentally observed phenomena and is required for adequate quantitative analytical modeling of the residual stresses in matrix composites.
Scanning manufacturing parameters determining the residual stress state in LPBF IN718 small parts
(2021)
The influence of scan strategy on the residual stress (RS) state of an as-built IN718 alloy produced by means of laser powder bed fusion (LPBF) is investigated. Two scan vector rotations (90 degrees-alternation and 67 degrees-rotation), each produced following two different scan vector lengths (long and short), are used to manufacture four rectangular prisms. Neutron diffraction (ND) and laboratory X-ray diffraction (XRD) techniques are used to map the bulk and surface RS state, respectively. The distortion induced upon removal from the baseplate is measured via profilometry. XRD measurements show that the two long scan vector strategies lead to higher RS when compared with the equivalent short scan vector strategies. Also, the 67 degrees-rotation strategies generate lower RS than their 90 degrees-alternation counterparts. Due to the lack of reliable stress-free d0 references, the ND results are analyzed using von Mises stress. In general, ND results show significant RS spatial non-uniformity. A comparison between ND and distortion results indicates that the RS component parallel to the building direction (Z-axis) has a predominant role in the Z-displacement. The use of a stress balance scheme allows to discuss the d0 variability along the length of the specimens, as well as examine the absolute RS state.