Overview of Materials Qualification Needs for Metal Additive Manufacturing

By M. Seifi, Ayman Salem, Jack L. Beuth, Ola L. A. Harrysson, J. Lewandowski. 2016

562 citations recorded by the source corpus.

This overview highlights some of the key aspects regarding materials qualification needs across the additive manufacturing (AM) spectrum. AM technology has experienced considerable publicity and growth in the past few years with many successful insertions for non-mission-critical applications. However, to meet the full potential that AM has to offer, especially for flight-critical components (e.g., rotating parts, fracture-critical parts, etc.), qualification and certification efforts are necessary. While development of qualification standards will address some of these needs, this overview outlines some of the other key areas that will need to be considered in the qualification path, including various process-, microstructure-, and fracture-modeling activities in addition to integrating these with lifing activities targeting specific components. Ongoing work in the Advanced Manufacturing and Mechanical Reliability Center at Case Western Reserve University is focusing on fracture and fatigue testing to rapidly assess critical mechanical properties of some titanium alloys before and after post-processing, in addition to conducting nondestructive testing/evaluation using micro-computerized tomography at General Electric. Process mapping studies are being conducted at Carnegie Mellon University while large area microstructure characterization and informatics (EBSD and BSE) analyses are being conducted at Materials Resources LLC to enable future integration of these efforts via an Integrated Computational Materials Engineering approach to AM. Possible future pathways for materials qualification are provided.

Subfields: Automotive Engineering, Materials Chemistry, Mechanical Engineering

View Paper: https://www.semanticscholar.org/paper/108805c5f6680e69fd4d621c54b6a5b5096bdc27

How researchers see this paper

The researchers whose trusted networks rank it highest, strongest advocate first. Every researcher gets a different order.

In Automotive Engineering

In Materials Chemistry

In Mechanical Engineering

Citations in the corpus

Advances in Metal Additive Manufacturing: A Review of Common Processes, Industrial Applications, and Current Challenges (2021, background): “Today, designers can select from a range of metal materials such as Stainless Steel, Gold, Silver, Inconel, Copper, Titanium alloys, Nickle-based superalloys, tool steels, Aluminium alloys, Platinum, Palladium, and Tantalum [158,159].”
Effects of defects on mechanical properties in metal additive manufacturing: A review focusing on X-ray tomography insights (2020, background): “The use of X-ray tomography for inspection and qualification of additively manufactured parts was discussed in detail in [55,56] and the need for more detailed “effect of defect studies” was highlighted in these papers.”
Mechanical anisotropy of additively manufactured stainless steel 316L: An experimental and numerical study (2021, background): “These issues are eported to prevent additive manufacturing from mass adoption in afety-critical environments [5].”
Qualification of AM parts: Extreme value statistics applied to tomographic measurements (2017, methodology): “All the analyses presented were obtained considering a constant defect density, but we saw in Section 3 that this hypothesis could be oversimplified [3].”
Additive Manufacturing of Metallic Materials: A Review (2017, background): “Additional review articles include the material properties and qualifications, as well as the economic or environmental impacts of AM processes [33, 34].”
Review: The Impact of Metal Additive Manufacturing on the Aerospace Industry (2019, background): “Unlike the investigation of static properties in which conventional standards can be modified to cater for AM materials, the utilization of established standards for fatigue testing for CM metallic parts such as ASTM E0466, ASTM E0606, ISO 1099:2006, and ISO 1143:2010 could pose challenges and uncer”
Simulation of metal additive manufacturing microstructures using kinetic Monte Carlo (2017, background): “The need for computationally efficient techniques to predict varying characteristics of AM-produced components, at the scale of experimental builds, has been identified by many researchers [3,25,27].”