Krzysztof S. Stopka, Andrew Desrosiers, Amber Andreaco, Michael D. Sangid
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引用次数: 0
摘要
快速成型制造(AM)可以制造出网状或近似网状的部件,同时构建材料的微观结构,从而将材料成型和部件成型紧密结合在一起,这与传统制造工艺截然不同。虽然自动成型技术的优点众所周知,但在疲劳受限的应用中广泛采用自动成型技术却受到缺陷的阻碍,例如非正常工艺条件导致的气孔。大量的 AM 工艺参数和条件使得在鉴定过程中难以捕捉导致疲劳设计允许值的孔隙率变化。此外,悬伸和薄壁等几何特征会影响局部导热性,从而影响局部缺陷和微观结构。因此,对零件内的 AM 材料进行材料性能鉴定并不总是一项简单的任务。本文介绍了一种快速鉴定 AM 疲劳受限零件的方法,主要包括三个方面:(1)在 AM 试样中植入特定尺寸、分布和形态的孔隙缺陷;(2)结合非破坏性和破坏性技术进行材料表征和机械疲劳测试;(3)对特定孔隙缺陷和微观结构组合产生的疲劳行为进行基于微观结构的模拟。所提出的方法可生成模拟数据,以验证和/或增强实验疲劳数据集,从而减少所需的测试次数,促进更快速地获得 AM 材料鉴定。此外,这项工作还建议将材料鉴定与零件认证更紧密地结合起来,以确定 AM 零件内不同区域的材料属性。
A Methodology for the Rapid Qualification of Additively Manufactured Materials Based on Pore Defect Structures
Additive manufacturing (AM) can create net or near-net-shaped components while simultaneously building the material microstructure, therefore closely coupling forming the material and shaping the part in contrast to traditional manufacturing with distinction between the two processes. While there are well-heralded benefits to AM, the widespread adoption of AM in fatigue-limited applications is hindered by defects such as porosity resulting from off-nominal process conditions. The vast number of AM process parameters and conditions make it challenging to capture variability in porosity that drives fatigue design allowables during qualification. Furthermore, geometric features such as overhangs and thin walls influence local heat conductivity and thereby impact local defects and microstructure. Consequently, qualifying AM material within parts in terms of material properties is not always a straightforward task. This article presents an approach for rapid qualification of AM fatigue-limited parts and includes three main aspects: (1) seeding pore defects of specific size, distribution, and morphology into AM specimens, (2) combining non-destructive and destructive techniques for material characterization and mechanical fatigue testing, and (3) conducting microstructure-based simulations of fatigue behavior resulting from specific pore defect and microstructure combinations. The proposed approach enables simulated data to be generated to validate and/or augment experimental fatigue data sets with the intent to reduce the number of tests needed and promote a more rapid route to AM material qualification. Additionally, this work suggests a closer coupling between material qualification and part certification for determining material properties at distinct regions within an AM part.
期刊介绍:
The journal will publish: Research that supports building a model-based definition of materials and processes that is compatible with model-based engineering design processes and multidisciplinary design optimization; Descriptions of novel experimental or computational tools or data analysis techniques, and their application, that are to be used for ICME; Best practices in verification and validation of computational tools, sensitivity analysis, uncertainty quantification, and data management, as well as standards and protocols for software integration and exchange of data; In-depth descriptions of data, databases, and database tools; Detailed case studies on efforts, and their impact, that integrate experiment and computation to solve an enduring engineering problem in materials and manufacturing.