Structural Integrity of Additive Manufactured Parts
Transcript of Structural Integrity of Additive Manufactured Parts
ASTM INTERNATIONAL Helping our world work better
ISBN: 978-0-8031-7686-7 Stock #: STP1620
www.astm.org
ASTM INTERNATIONAL Selected Technical Papers
Structural Integrity of Additive Manufactured Parts
STP 1620Editors: Nima ShamsaeiSteve DaniewiczNik Hrabe
Structural Integrity of Additive M
anufactured PartsS
hamsaei | D
aniewicz | H
rabe | B
eretta | Waller | S
eifiS
TP 1620
Stefano BerettaJess WallerMohsen Seifi
SELECTED TECHNICAL PAPERS
STP1620
Editors: Nima Shamsaei, Steve Daniewicz, Nik Hrabe, Stefano Beretta,Jess Waller, and Mohsen Seifi
Structural Integrity ofAdditive ManufacturedParts
ASTM STOCK #STP1620DOI: 10.1520/STP1620-EB
ASTM International, 100 Barr Harbor Drive, PO Box C700, West Conshohocken, PA 19428-2959Printed in the U.S.A.
Library of Congress Cataloging-in-Publication Data
Names: Shamsaei, Nima, editor. | ASTM International, issuing body.
Title: Structural integrity of additive manufactured parts / editors, Nima
Shamsaei, Steve Daniewicz, Nik Hrabe, Stefano Beretta, Jess Waller,
Mohsen Seifi.
Description: West Conshohocken, PA : ASTM International, 2020. | Series:
Selected technical papers ; STP1620 | Includes bibliographical
references. | Summary: "This compilation of Selected Technical Papers,
STP1620, Structural Integrity of Additive Manufactured Parts, contains
peer-reviewed papers that were presented at a symposium held November
6-8, 2018, in Washington, DC, USA. The symposium was sponsored by ASTM
International Committee F42 on Additive Manufacturing Technologies, with
co-sponsorship from Committees E08 on Fatigue and Fracture and E07 on
Nondestructive Testing"-- Provided by publisher.
Identifiers: LCCN 2019055470 (print) | LCCN 2019055471 (ebook) | ISBN
9780803176867 (paperback) | ISBN 9780803176874 (pdf)
Subjects: LCSH: Three-dimensional printing--Congresses. | Machine
parts--Testing--Congresses. | Machine parts--Design and
construction--Congresses.
Classification: LCC TS171.95 .S77 2020 (print) | LCC TS171.95 (ebook) |
DDC 621.9/88--dc23
LC record available at https://lccn.loc.gov/2019055470
LC ebook record available at https://lccn.loc.gov/2019055471
ISBN: 978-0-8031-7686-7
Copyright VC 2020 ASTM INTERNATIONAL, West Conshohocken, PA. All rights reserved. This material
may not be reproduced or copied, in whole or in part, in any printed, mechanical, electronic, film, or other
distribution and storage media, without the written consent of the publisher.
Photocopy Rights
Authorization to photocopy items for internal, personal, or educational classroom use, or the internal,
personal, or educational classroom use of specific clients, is granted by ASTM International provided that
the appropriate fee is paid to the Copyright Clearance Center, 222 Rosewood Drive, Danvers, MA 01923,
Tel: (978) 646-2600; http://www.copyright.com/
ASTM International is not responsible, as a body, for the statements and opinions expressed in this
publication. ASTM International does not endorse any products represented in this publication.
Peer Review Policy
Each paper published in this volume was evaluated by two peer reviewers and at least one editor. The
authors addressed all of the reviewers’ comments to the satisfaction of both the technical editor(s) and
the ASTM International Committee on Publications.
The quality of the papers in this publication reflects not only the obvious efforts of the authors and the
technical editor(s), but also the work of the peer reviewers. In keeping with long-standing publication
practices, ASTM International maintains the anonymity of the peer reviewers. The ASTM International
Committee on Publications acknowledges with appreciation their dedication and contribution of time
and effort on behalf of ASTM International.
Citation of Papers
When citing papers from this publication, the appropriate citation includes the paper authors, “paper
title,” in STP title, book editor(s) (West Conshohocken, PA: ASTM International, year), page range, paper
doi, listed in the footnote of the paper. A citation is provided on page one of each paper.
Printed in Hanover, PA
May, 2020
Foreword
THIS COMPILATION OF Selected Technical Papers, STP1620, Structural Integrityof Additive Manufactured Parts, contains peer-reviewed papers that were presented ata symposium held November 6–8, 2018, in Washington, DC, USA. The symposiumwas sponsored by ASTM International Committee F42 on Additive ManufacturingTechnologies, with co-sponsorship from Committees E08 on Fatigue and Fractureand E07 on Nondestructive Testing.
Symposium Chairs and STP Editors:
Nima ShamsaeiAuburn UniversityAuburn, AL, USA
Steve DaniewiczThe University of Alabama
Tuscaloosa, AL, USA
Nik HrabeNational Institute of Standards and Technology
Boulder, CO, USA
Stefano BerettaPolitecnico di Milano
Milan, Italy
Jess WallerNational Aeronautics and Space Administration, HX5
Las Cruces, NM, USA
Mohsen SeifiASTM International
Washington, DC, USA
iii
Contents
Overview ix
Metal Additive Manufacturing Defect Formation and Nondestructive
Evaluation Detectability 1
Ben Dutton, Wilson Vesga, Jess Waller, Steve James, and Mohsen Seifi
Evaluation of Nondestructive Volumetric Testing Methods for
Additively Manufactured Parts 51
Anne-Françoise Obaton, Bryan Butsch, Stephen McDonough,
Ewen Carcreff, Nans Laroche, Yves Gaillard, Jared B. Tarr, Patrick Bouvet,
Rodolfo Cruz, and Alkan Donmez
NDE-Based Quality Assurance of Metal Additively Manufactured Aerospace
Parts at NASA, JAXA, and ESA 92
Jess M. Waller, Eric R. Burke, Douglas N. Wells, Charles T. Nichols,
Ana D. Brandao, Johannes Gumpinger, Martin Born, Tommaso Ghidini,
Tsuyoshi Nakagawa, Akio Koike, Masami Mitsui, and Tsuyoshi Itoh
Eddy Current Technologies for Real-Time Monitoring and Post-Process
Examination of Laser Powder Bed Fusion Process 129
Evgueni Iordanov Todorov
Nondestructive Evaluation of Additive Manufactured Parts
Using Process Compensated Resonance Testing 165
Richard A. Livings, Eric J. Biedermann, Chen Wang, Thomas Chung,
Steven James, Jess M. Waller, Scott Volk, Ajay Krishnan, and Shane Collins
Nondestructive Evaluation of Programmed Defects in
Ti-6Al-4V L-PBF ASTM E8-Compliant Dog-Bone Samples 206
Jeong K. Na, John Middendorf, Michael Lander, Jess M. Waller,
and Richard W. Rauser
v
Expression of Additive Manufacturing Surface Irregularities through
a Flaw-Based Assessment 234
Johannes Gumpinger, Ana D. Brandao, Emilie Beevers,
Thomas Rohr, Tommaso Ghidini, Stefano Beretta, and Simone Romano
Development and Testing of 316L Stainless Steel Metal Additive Manufacturing
Test Articles for Powder Bed Fusion and Directed Energy Deposition Processes 250
Jessica L. Coughlin, Trevor G. Hicks, Patrick S. Dougherty,
and Steven A. Attanasio
Effects of the Shielding Argon Gas Flow on the Mechanical and
Physical Properties of Selective Laser Melted Ti-6Al-4V Solid Material 278
Oscar A. Quintana, Nia Hightower, and Robert Rybolt
Influence of Intentionally Induced Porosity and Postprocessing Conditions
on the Mechanical Properties of Laser Powder Bed-Fused Inconel 625 294
Jean-Rene Poulin, Morgan Letenneur, Patrick Terriault, and Vladimir Brailovski
Elucidating the Impact of Processing Parameters of Additive Manufactured
Materials Using Microscale Tensile Samples 313
Michael Duffy, Salahudin Nimer, Marc Zupan, and Steven Storck
Additive Manufactured Polymer Test Coupons: Issues and Solutions 334
Rachael Andrulonis, Royal Lovingfoss, and John Tomblin
Coupon-Level Mechanical Testing for Polymer-Based Additive Manufacturing 355
Chul Y. Park, Keith E. Rupel, Chelsey E. Henry, and Upul R. Palliyaguru
Characterization of Stress Fields Near Pores and Application to Fatigue Lives 367
James C. Sobotka and R. Craig McClung
Fatigue and Fracture Behavior of Additively Manufactured Austenitic Stainless Steel 381
Chris San Marchi, Thale R. Smith, Joshua D. Sugar, and Dorian K. Balch
Fatigue Behavior of Laser Metal Deposited 17-4 PH Stainless Steel 399
Lakshmi J. Vendra, Anjani Achanta, and Eric Sullivan
Fatigue Assessment of 17-4 PH Stainless Steel Notched Specimens Made
by Direct Metal Laser Sintering 415
Filippo Berto, Ali Fatemi, Nima Shamsaei, and Seyed Mohammad Javad Razavi
A Comparison of Stress Corrosion Cracking Susceptibility in
Additively Manufactured Ti-6Al-4V for Biomedical Applications 423
Michael Roach, R. Scott Williamson, Jonathan Pegues, and Nima Shamsaei
Fatigue Properties of Additive Manufactured Ti-6Al-4V and
CoCr-Alloy Total Ankle Components 437
Dirk Scholvin, Doug Linton, David Tuttle, Ben Walters, Scott Bible,
Jesse Fleming, and Jon Moseley
vi
Primary Processing Parameter Effects on Defects and Fatigue in Alloy 718 450
Luke Sheridan, Bo Whip, and Joy Gockel
Role of Post-Fabrication Heat Treatment on the Low-Cycle Fatigue
Behavior of Electron Beam Melted Inconel 718 Superalloy 465
Thomas Wegener, Johannes Gunther, Florian Brenne, and Thomas Niendorf
An Efficient Test Method for the Quantification of Technology-Dependent
Factors Affecting the Fatigue Behavior of Metallic Additive
Manufacturing Components 484
Gianni Nicoletto
Probabilistic Computational Fatigue and Fracture Modeling of
Additive Manufactured Components 507
Robert G. Tryon, Robert McDaniels, Andrew Chern, Michael Oja,
Animesh Dey, Ibrahim Awad, and Chad Duty
Probabilistic Framework for Defect Tolerant Fatigue Assessment of
Additively Manufactured Parts Applied to a Space Component 526
Simone Romano, Stefano Beretta, Stefano Miccoli, and Michael Gschweitl
Rapid Additive Qualification Using Probabilistics (RAQUP) 540
Genghis Khan, Natarajan Chennimalai Kumar, Liping Wang,
Vipul Gupta, Voramon Dheeradhada, Tim Hanlon, Laura Dial,
and Joseph Vinciquerra
Performance Signature Qualification for Additively Manufactured Parts
under Conditions Emulating In-Service Loading 550
John G. Michopoulos, John C. Steuben, Athanasios P. Iliopoulos,
Trung Nguyen, and Nam Phan
NASA’s Efforts for the Development of Standards for Additive
Manufactured Components 573
Richard Russell
vii
Overview
To ensure the structural integrity of additively manufactured (AM) parts, it is criti-cal to establish feedstock-process-structure-property-performance relationships,particularly where these components and structures are being used in safety-criticalapplications. ASTM International (ASTM), in coordination with partners fromgovernment, industry, and academia, has organized a series of annual symposia tohelp address these needs.
The 3rd ASTM Symposium on Structural Integrity of Additive ManufacturedParts—which took place from November 6–8, 2018, in Washington, DC—wasdesigned to provide a forum for the exchange of ideas regarding the structural in-tegrity of parts fabricated using AM, with a focus on the lack of industry standardsand design principles, as well as qualification and certification challenges.
The event was co-sponsored by ASTM Committee F42 on AdditiveManufacturing Technologies, along with Committees E08 on Fatigue and Fractureand E07 on Nondestructive Testing. It was supported by the ASTM AdditiveManufacturing Center of Excellence (AM CoE), National Aeronautics and SpaceAdministration (NASA), National Institute of Standards and Technology (NIST),European Structural Integrity Society (ESIS) TC15, and the U.S. National Congressfor Theoretical and Applied Mechanics.
Approximately 250 people attended the 3-day event, representing 11 differentnations around the world. The symposium included 56 talks by experts from indus-try, government, and academia, and 3 panel discussions, which covered nonde-structive testing and the challenges of AM standardization and adoption in themedical device and aerospace industries.
The 27 selected technical papers in this collection provide an opportunity todelve more deeply into the wide variety of topics covered during the symposium.While individual papers often touch on multiple topics, the following list presentsthe major areas covered in the symposium and the papers that address each topicas their primary focus.
A significant emphasis of this symposium was on nondestructive evaluationand in situ monitoring of AM parts, and the below articles are in this category:
� Metal Additive Manufacturing Defect Formation and Nondestructive Evalu-ation (NDE) Detectability
� Evaluation of Nondestructive Volumetric Testing Methods for AdditivelyManufactured Parts
ix
� NDE-Based Quality Assurance of Metal Additively Manufactured AerospaceParts at NASA, JAXA, and ESA
� Eddy Current Technologies for Real-time Monitoring and Post Process Exam-ination of Laser Powder Bed Fusion Process
� Nondestructive Evaluation of Additive Manufactured Parts Using ProcessCompensated Resonance Testing
� Nondestructive Evaluation of Programmed Defects in Ti-6Al-4V L-PBFASTM E8-Compliant Dog-Bone Samples
As the lack of understanding and standardization to capture the structural integrity ofAM parts is still a major roadblock against the adoption of AM in load-bearing, safetycritical applications, many papers presented relating to fatigue, fracture, tensile, andcorrosion behavior of materials and parts fabricated using AM were presented. Effectsof design, process, and post-process parameters on fatigue and fracture properties aswell as process optimization to improve structural integrity of AM parts were also dis-cussed extensively. Applicability of existing mechanical test methods to AM parts andinnovative approaches to standardization were emphasized in this symposium. Thefollowing papers focus on related topics for this category:
� Expression of Additive Manufacturing Surface Irregularities through a Flaw-Based Assessment
� Development and Testing of 316L Stainless Steel Metal Additive ManufacturingTest Articles for Powder Bed Fusion and Directed Energy Deposition Processes
� Effects of the Shielding Argon Gas Flow on the Mechanical and PhysicalProperties of Selective Laser Melted Ti-6Al-4V Solid Material
� Influence of Intentionally Induced Porosity and Postprocessing Conditions onthe Mechanical Properties of Laser Powder Bed-Fused Inconel 625
� Elucidating the Impact of Processing Parameters of Additive ManufacturedMaterials Using Microscale Tensile Samples
� Additive Manufactured Polymer Test Coupons—Issues and Solutions� Coupon-Level Mechanical Testing for Polymer Based Additive Manufacturing� Characterization of Stress Fields Near Pores and Application to Fatigue Lives� Fatigue and Fracture Behavior of Additively Manufactured Austenitic Stain-
less Steel� Fatigue Behavior of Laser Metal Deposited 17-4 PH Stainless Steel� Fatigue Assessment of 17-4 PH Stainless Steel Notched Specimens Made by
Direct Metal Laser Sintering� A Comparison of Stress Corrosion Cracking Susceptibility in Additively-
Manufactured Ti-6Al-4V for Biomedical Applications� Fatigue Properties of Additive Manufactured Ti-6Al-4V and CoCr-Alloy
Total Ankle Components
x
� Primary Processing Parameter Effects on Defects and Fatigue in Alloy 718� Role of Post-Fabrication Heat Treatment on the Low-Cycle Fatigue Behavior
of Electron Beam Melted Inconel 718 Superalloy� An Efficient Test Method for the Quantification of Technology-Dependent
Factors Affecting the Fatigue Behavior of Metallic AM Components� Probabilistic Computational Fatigue and Fracture Modeling of Additive
Manufactured Components� Probabilistic Framework for Defect Tolerant Fatigue Assessment of AM Parts
Applied to a Space Component
Finally, recent advances in standardization, qualification and certification werepresented:
� Rapid Additive Qualification Using Probabilistics (RAQUP)� Performance Signature Qualification for Additively Manufactured Parts un-
der Conditions Emulating In-Service Loading� NASA’s Efforts for the Development of Standards for Additive Manufactured
Components
We would like to extend our gratitude to everyone who made this symposium pos-sible. The hard work of the authors, coauthors, our symposium co-chairs and co-editors, peer reviewers, and personnel of ASTM and its AM CoE partners, as wellas the support of NASA, NIST, ESIS TC15, and the U.S. National Congress for The-oretical and Applied Mechanics all played a major role in the success of the sympo-sium and this publication.
Nima ShamsaeiMohsen SeifiSTP Editors
xi
ASTM INTERNATIONAL Helping our world work better
ISBN: 978-0-8031-7686-7 Stock #: STP1620
www.astm.org