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Long-term Process Stability in Additive Manufacturing

ADDITIVE MANUFACTURING(2023)

Sandia Natl Labs

Cited 5|Views30
Abstract
Laser powder bed fusion (L-PBF), also known as selective laser sintering or direct laser melting, is an additive manufacturing process in which part geometries are formed simultaneously with the underlying material. The microstructure, defect content, and surface quality are all synthesized conjointly with the part shape. While the geometric design freedom allowed by this process enables new complex features and parts with small (similar to 1 mm) features, challenges associated with process qualification can deter wider adoption. Furthermore, a lack of historical performance data for statistical process control of witness coupons, for either bulk material or for small features, makes the barrier to entry more difficult. Here, we demonstrate long-term, property-based process monitoring and variability assessment using both small-featured (1 mm) and larger, bulk-representative material witness coupons. Over a one-year period, more than 550 tensile bars and 80 Charpy impact bars were printed alongside 316 L stainless steel parts built using L-PBF and tested to detect shifts in the process over time. Miniature tensile bars with a 1 mm(2 )gage area were tested using a high throughput mechanical testing system. In parallel, a larger test coupon was used to monitor density, hardness, and Charpy impact toughness. This collection of measurements was used to determine detectable property shifts correlated to L-PBF process changes including powder feedstock, machine hardware, software versioning, and machine parameter settings. The benefits of using small featured, high-throughput samples are discussed based on process sensitivity and the number of repeat tests possible for each build. This study not only reveals the utility of property-based process monitoring but illustrates the sensitivity of these measurements to detect process changes and provides further evidence for property stability in modern L-PBF.
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Statistical process control,Witness coupon,AM process monitoring,AM process qualification
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要点】:本研究通过长期监测和评估小特征(1mm)和大特征代表性材料见证样件,展示了基于性能的增材制造过程监控和变异性评估,突显了激光粉末床熔化(L-PBF)工艺的长期性能稳定性。

方法】:采用了一年以上的时间跨度,打印了550多个拉伸条和80多个夏比冲击条,以及使用L-PBF工艺制作的316L不锈钢零件,通过高效率的机械测试系统对1mm²标距面积的微型拉伸条进行测试,同时对较大见证样件进行了密度、硬度和夏比冲击韧性的监测。

实验】:研究通过对比分析小特征高效率样本的测量数据,确定了与L-PBF过程变化(包括粉末原料、机器硬件、软件版本和机器参数设置)相关的可检测性能变化。结果表明,基于性能的过程监控的有效性,以及这些测量对于检测过程变化的高度敏感性,进一步证实了现代L-PBF工艺的性能稳定性。