3009 Additive Manufacturing Build Interruption Effects (AMBIE)

3009_ProjectProfile_Graphic

Data matrix related to tensile testing, hardness testing, and metallurgical characterization between control specimens (no interrupt) and build interrupt specimens for various build time delays in AlSi10Mg and IN625.

Problem
Objective
Technical Approach
Project Participants
Problem

The full fabrication time in laser powder bed fusion (LPBF) can range from a couple of hours to several days depending on the complexity of the part.  During the build cycle, both planned process interruptions (such as powder refill) and unplanned process interruptions (such as power outages) can occur that may last up to several hours.  A decision must be made, typically based on project guidelines rather than data driven analysis, of whether to restart the build from that point or start it from the beginning.  The restart usually results in the part exhibiting a seam line.  This project addresses the lack of knowledge available in the public domain detailing the effects of build interruptions on the properties of the resulting parts.

Objective

The objective of the project is to develop a comprehensive data set of build interruptions for two commonly used alloys (AlSi10Mg and IN625) processed with LPBF.   The compiled data sets can be used by government and industry to decide whether it is best to resume the fabrication process or to start the build from the beginning. Considerations include the microstructure and material properties of the component as well as fabrication cost and time.

Technical Approach

The project aims to characterize build interruption effects and develop recovery procedures for two materials (AlSi10Mg and IN625) that have a wide base of industrial applications. Two commercially available LBPF systems (SLM 125 HL and AconityONE) are being used to produce samples for testing.

Phase I approach is to characterize the effects to the microstructure and mechanical properties from build interruptions on both the SLM 125 HL and AconityONE systems using AlSi10Mg material. At the end of Phase I, a comparison of the results on the different systems for this material is planned.

Phase II approach is to provide similar characterization and monitoring methodology for IN625 processed on the SLM 125 HL system.  Upon completion of this phase, the comparison of build interruptions using both materials (AlSi10Mg and IN625) on the SLM 125 HL is to be completed.

Project Participants

Project Principal

University of Texas at El Paso (UTEP) Logo

Public Participants

  • U.S. Department of Defense
  • National Science Foundation
  • U.S. Department of Energy

Project Summary

Updated: January 17, 2019

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