Additive manufacturing (AM) comprises a host of promising technologies that have several advantages over traditional methods of fabrication. In this work, the relationship between processing parameters, defect populations, and resulting mechanical behavior is explored. A wide spectrum of AM methods and materials are considered, including Laser Powder Bed Fusion (LPBF) AlSi10Mg, Electron Beam Melted (EBM) Ti-6Al-4V, and Binder Jet 17-4 SS and 4340 steel. For each of these, CT scans and Ultrasonic Fatigue tests have been conducted and correlations drawn between them and the underlying processing parameters. Effects of surface finish were also examined. Implications for the design and fabrication of critical components for aerospace applications will be discussed.
Learning Objectives:
- Understand key parameter/defect/performance relationships across three major materials systems on multiple AM modalities.
- Describe rapid qualification techniques that can be used to quickly screen for improved
- Understand the basics of ultrasonic fatigue testing.
