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<p>Current approaches for additive manufacturing (AM) process qualification treat each AM system as unique. This results in substantial non-recurring engineering costs to scale production. Here, we test a low-cost, quality assurance-based alternative where variations in subsystem performance are used to predict variations in tensile and fatigue properties. Experiments spanning six builds and 300 specimens were designed to replicate historically measured ranges of subsystem performance. Specifically, differential pressure was used to modify the gas flow in the range of 1.1 to 3.3&#xa0;m/s, and laser defocus adjustment was used to modify the laser spot size in the range of 72 to 87 micrometers. Each mechanical testing result was contextualized by the gas flow speed, laser spot size, and laser ellipticity measured at the position the specimen was built. Furthermore, the interdependence between subsystem performance and specimen thermal history was probed by including specimens with different support structures. All other parameters were chosen to minimize uncontrolled variation. Pearson’s correlation and ANOVA show the measured correlation between material properties and laser subsystem performance is generally stronger than the correlation with gas flow subsystem performance. Finally, we demonstrate that fatigue results were improved within a subsystem performance-based quality envelope.</p>

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The Effects of Subsystem Performance on Static and Dynamic Properties of Inconel 718 Built with Laser Powder Bed Fusion

  • 期刊论文

  • 发表日期：

    2025年2月14日

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  • Alexander L. Kitt,
  • Ajay Krishnan,
  • Zachary Corey,
  • Luke Mohr,
  • Michael Taylor,
  • Cameron Carter,
  • Bryan Donahue,
  • Derek Zbikowski,
  • William C. Mohr,
  • David Hicks,
  • Ron Aman,
  • Amy Kiedrowski,
  • Ed Nemeth,
  • Jim Wolbers,
  • William E. Frazier,
  • Amberlee S. Haselhuhn

摘要

Current approaches for additive manufacturing (AM) process qualification treat each AM system as unique. This results in substantial non-recurring engineering costs to scale production. Here, we test a low-cost, quality assurance-based alternative where variations in subsystem performance are used to predict variations in tensile and fatigue properties. Experiments spanning six builds and 300 specimens were designed to replicate historically measured ranges of subsystem performance. Specifically, differential pressure was used to modify the gas flow in the range of 1.1 to 3.3 m/s, and laser defocus adjustment was used to modify the laser spot size in the range of 72 to 87 micrometers. Each mechanical testing result was contextualized by the gas flow speed, laser spot size, and laser ellipticity measured at the position the specimen was built. Furthermore, the interdependence between subsystem performance and specimen thermal history was probed by including specimens with different support structures. All other parameters were chosen to minimize uncontrolled variation. Pearson’s correlation and ANOVA show the measured correlation between material properties and laser subsystem performance is generally stronger than the correlation with gas flow subsystem performance. Finally, we demonstrate that fatigue results were improved within a subsystem performance-based quality envelope.