TY - JOUR A1 - D'Accardi, E. A1 - Krankenhagen, Rainer A1 - Ulbricht, Alexander A1 - Pelkner, Matthias A1 - Pohl, Rainer A1 - Palumbo, D. A1 - Galietti, U. T1 - Capability to detect and localize typical defects of laser powder bed fusion (L‑PBF) process: an experimental investigation with different non‑destructive techniques JF - Progress in Additive Manufacturing N2 - Additive manufacturing (AM) technologies, generally called 3D printing, are widely used because their use provides a high added value in manufacturing complex-shaped components and objects. Defects may occur within the components at different time of manufacturing, and in this regard, non-destructive techniques (NDT) represent a key tool for the quality control of AM components in many industrial fields, such as aerospace, oil and gas, and power industries. In this work, the capability of active thermography and eddy current techniques to detect real imposed defects that are representative of the laser powder bed fusion process has been investigated. A 3D complex shape of defects was revealed by a μCT investigation used as reference results for the other NDT methods. The study was focused on two different types of defects: porosities generated in keyhole mode as well as in lack of fusion mode. Different thermographic and eddy current measurements were carried out on AM samples, providing the capability to detect volumetric irregularly shaped defects using non-destructive methods. KW - Additive Manufacturing KW - Defect detection KW - Thermography KW - Eddy-current testing KW - Micro-computed tomography PY - 2022 UR - https://nbn-resolving.org/urn:nbn:de:kobv:b43-546680 DO - https://doi.org/10.1007/s40964-022-00297-4 SN - 2363-9512 VL - 7 IS - 6 SP - 1239 EP - 1256 PB - Springer AN - OPUS4-54668 LA - eng AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - JOUR A1 - Schröder, Jakob A1 - Evans, Alexander A1 - Mishurova, Tatiana A1 - Ulbricht, Alexander A1 - Sprengel, Maximilian A1 - Serrano Munoz, Itziar A1 - Fritsch, Tobias A1 - Kromm, Arne A1 - Kannengießer, Thomas A1 - Bruno, Giovanni T1 - Diffraction-Based Residual Stress Characterization in Laser Additive Manufacturing of Metals JF - Metals N2 - Laser-based additive manufacturing methods allow the production of complex metal structures within a single manufacturing step. However, the localized heat input and the layer-wise manufacturing manner give rise to large thermal gradients. Therefore, large internal stress (IS) during the process (and consequently residual stress (RS) at the end of production) is generated within the parts. This IS or RS can either lead to distortion or cracking during fabrication or in-service part failure, respectively. With this in view, the knowledge on the magnitude and spatial distribution of RS is important to develop strategies for its mitigation. Specifically, diffraction-based methods allow the spatial resolved determination of RS in a non-destructive fashion. In this review, common diffraction-based methods to determine RS in laser-based additive manufactured parts are presented. In fact, the unique microstructures and textures associated to laser-based additive manufacturing processes pose metrological challenges. Based on the literature review, it is recommended to (a) use mechanically relaxed samples measured in several orientations as appropriate strain-free lattice spacing, instead of powder, (b) consider that an appropriate grain-interaction model to calculate diffraction-elastic constants is both material- and texture-dependent and may differ from the conventionally manufactured variant. Further metrological challenges are critically reviewed and future demands in this research field are discussed. KW - Laser-based additive manufacturing KW - Residual stress analysis KW - X-ray and neutron diffraction KW - Diffraction-elastic constants KW - Strain-free lattice spacing PY - 2021 UR - https://nbn-resolving.org/urn:nbn:de:kobv:b43-538054 DO - https://doi.org/10.3390/met11111830 VL - 11 IS - 11 SP - 1830 PB - MPDI CY - Basel AN - OPUS4-53805 LA - eng AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - JOUR A1 - Serrano Munoz, Itziar A1 - Ulbricht, Alexander A1 - Fritsch, Tobias A1 - Mishurova, Tatiana A1 - Kromm, Arne A1 - Hofmann, M. A1 - Wimpory, R. C. A1 - Evans, Alexander A1 - Bruno, Giovanni T1 - Scanning Manufacturing Parameters Determining the Residual Stress State in LPBF IN718 Small Parts JF - Advanced engineering materials N2 - The influence of scan strategy on the residual stress (RS) state of an as-built IN718 alloy produced by means of laser powder bed fusion (LPBF) is investigated. Two scan vector rotations (90°-alternation and 67°-rotation), each produced following two different scan vector lengths (long and short), are used to manufacture four rectangular prisms. Neutron diffraction (ND) and laboratory X-ray diffraction (XRD) techniques are used to map the bulk and surface RS state, respectively. The distortion induced upon removal from the baseplate is measured via profilometry. XRD measurements show that the two long scan vector strategies lead to higher RS when compared with the equivalent short scan vector strategies. Also, the 67°-rotation strategies generate lower RS than their 90°-alternation counterparts. Due to the lack of reliable stress-free d0 references, the ND results are analyzed using von Mises stress. In general, ND results show significant RS spatial non-uniformity. A comparison between ND and distortion results indicates that the RS component parallel to the building direction (Z-axis) has a predominant role in the Z-displacement. The use of a stress balance scheme allows to discuss the d0 variability along the length of the specimens, as well as examine the absolute RS state. KW - As-built LPBF IN718 alloy KW - Scan strategy influence KW - Neutron diffraction KW - Residual stress state KW - Stress balance condition KW - Distortion PY - 2021 UR - https://nbn-resolving.org/urn:nbn:de:kobv:b43-526360 DO - https://doi.org/10.1002/adem.202100158 VL - 23 IS - 7 SP - 158 PB - Wiley AN - OPUS4-52636 LA - eng AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - JOUR A1 - Mishurova, Tatiana A1 - Sydow, B. A1 - Thiede, Tobias A1 - Sizova, I. A1 - Ulbricht, Alexander A1 - Bambach, M. A1 - Bruno, Giovanni T1 - Residual Stress and Microstructure of a Ti-6Al-4V Wire Arc Additive Manufacturing Hybrid Demonstrator JF - Metals N2 - Wire Arc Additive Manufacturing (WAAM) features high deposition rates and, thus, allows production of large components that are relevant for aerospace applications. However, a lot of aerospace parts are currently produced by forging or machining alone to ensure fast production and to obtain good mechanical properties; the use of these conventional process routes causes high tooling and material costs. A hybrid approach (a combination of forging and WAAM) allows making production more efficient. In this fashion, further structural or functional features can be built in any direction without using additional tools for every part. By using a combination of forging basic geometries with one tool set and adding the functional features by means of WAAM, the tool costs and material waste can be reduced compared to either completely forged or machined parts. One of the factors influencing the structural integrity of additively manufactured parts are (high) residual stresses, generated during the build process. In this study, the triaxial residual stress profiles in a hybrid WAAM part are reported, as determined by neutron diffraction. The analysis is complemented by microstructural investigations, showing a gradient of microstructure (shape and size of grains) along the part height. The highest residual stresses were found in the transition Zone (between WAAM and forged part). The total stress range showed to be lower than expected for WAAM components. This could be explained by the thermal history of the component. KW - Additive manufacturing KW - Neutron diffraction KW - Residual stress KW - Hybrid manufacturing KW - WAAM KW - Ti-6Al-4V PY - 2020 UR - https://nbn-resolving.org/urn:nbn:de:kobv:b43-508245 DO - https://doi.org/10.3390/met10060701 VL - 10 IS - 6 SP - 701 PB - MDPI AN - OPUS4-50824 LA - eng AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - JOUR A1 - Scholz, Philipp A1 - Ulbricht, Alexander A1 - Joshi, Y. A1 - Gollwitzer, Christian A1 - Weidner, Steffen T1 - Microstructure of polymer-imprinted metal–organic frameworks determined by absorption edge tomography JF - International Journal of Materials Research (IJMR) N2 - Mechanochemically synthesized metal–organic Framework material HKUST-1 in combination with acrylonitrile butadiene styrene polymer was used to form a polymer metal–organic framework composite material by a simple extruder. This composite filament was used for 3D printing. Xray diffraction measurements were used to prove the homogeneous distribution of the metal–organic framework in the polymer on a centimeter scale, whereas X-ray Absorption Edge Tomography using a synchrotron radiation source was able to evaluate the 3D distribution of the metal–organic framework material both in the filament and the resultant printed sample with a resolution of a few lm. Our very first data indicate that, apart from a few clusters having significantly higher Cu concentration, HKUST-1 is distributed homogeneously down to the 100 lm length scale in both polymer bulk materials in the form of clusters with a size of a few lm. Absorption Edge Tomography in combination with data fusion also allows for the calculation of the metal–organic framework amount located on the external polymer surface. KW - MOF KW - Polymer KW - AET PY - 2019 DO - https://doi.org/10.3139/146.111817 SN - 1862-5282 SP - 1 EP - 10 PB - Carl Hanser Verlag AN - OPUS4-49483 LA - eng AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - JOUR A1 - Ulbricht, Alexander A1 - Gollwitzer, Christian A1 - Kupsch, Andreas A1 - Léonard, Fabien A1 - Müller, Bernd R. A1 - Oesch, Tyler A1 - Onel, Yener A1 - Thiede, Tobias A1 - Zscherpel, Uwe ED - Puente León, F. ED - Zagar, B. T1 - Moderne Methoden der CT-gestützten Strukturanalyse T1 - Modern techniques of CT based structure analysis JF - tm - Technisches Messen N2 - Durch den großflächigen Einsatz der Computertomographie (CT) in unterschiedlichen Industriebereichen steigen auch die Anforderungen an die quantitative Bildanalyse. Subjektive Bildwahrnehmung muss durch objektive Algorithmen ersetzt werden. In diesem Artikel stellt die Bundesanstalt für Materialforschung und -prüfung (BAM), die seit den 1980er Jahren an der Entwicklung der industriellen CT beteiligt ist, anhand ausgewählter Beispiele den aktuellen Stand ihrer Analysemethoden an verschiedenen Anwendungsbeispielen der CT vor. N2 - The increasing use of computed tomography (CT) in various industrial sectors requires more sophisticated techniques of quantitative image analysis. Subjective image perception needs to be replaced by objective algorithms. The German Federal Institute for Materials Research and Testing (BAM) has been involved in the development of industrial CT since the 1980s. This paper summarizes the current status of quantitative 3D image analysis techniques based on selected examples. KW - Computed tomography KW - Computertomographie KW - Röntgen-Refraktion KW - X-Ray refraction KW - Schadensanalyse KW - Damage analysis KW - Normung KW - standardization PY - 2020 DO - https://doi.org/10.1515/teme-2019-0125 SN - 0171-8096 SN - 2196-7113 VL - 87 IS - 2 SP - 81 EP - 91 PB - de Gruyter CY - Berlin AN - OPUS4-50337 LA - deu AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - JOUR A1 - Serrano Munoz, Itziar A1 - Fritsch, Tobias A1 - Mishurova, Tatiana A1 - Trofimov, Anton A1 - Apel, D. A1 - Ulbricht, Alexander A1 - Kromm, Arne A1 - Hesse, René A1 - Evans, Alexander A1 - Bruno, Giovanni T1 - On the interplay of microstructure and residual stress in LPBF IN718 JF - Journal of Material Science N2 - The relationship between residual stresses and microstructure associated with a laser powder bed fusion (LPBF) IN718 alloy has been investigated on specimens produced with three different scanning strategies (unidirectional Y-scan, 90° XY-scan, and 67° Rot-scan). Synchrotron X-ray energy-dispersive diffraction (EDXRD) combined with optical profilometry was used to study residual stress (RS) distribution and distortion upon removal of the specimens from the baseplate. The microstructural characterization of both the bulk and the nearsurface regions was conducted using scanning electron microscopy (SEM) and electron backscatter diffraction (EBSD). On the top surfaces of the specimens, the highest RS values are observed in the Y-scan specimen and the lowest in the Rot-scan specimen, while the tendency is inversed on the side lateral surfaces. A considerable amount of RS remains in the specimens after their removal from the baseplate, especially in the Y- and Z-direction (short specimen Dimension and building direction (BD), respectively). The distortion measured on the top surface following baseplate thinning and subsequent removal is mainly attributed to the amount of RS released in the build direction. Importantly, it is observed that the additive manufacturing microstructures challenge the use of classic theoretical models for the calculation of diffraction elastic constants (DEC) required for diffraction-based RS analysis. It is found that when the Reuß model is used for the calculation of RS for different crystal planes, as opposed to the conventionally used Kröner model, the results exhibit lower scatter. This is discussed in context of experimental measurements of DEC available in the literature for conventional and additively manufactured Ni-base alloys. KW - L-PBF IN718 material KW - Effect of scanning strategies KW - Near-surface X-ray diffraction KW - Residual stress in AM KW - Distortion upon baseplate removal PY - 2020 UR - https://nbn-resolving.org/urn:nbn:de:kobv:b43-519460 DO - https://doi.org/10.1007/s10853-020-05553-y SN - 0022-2461 VL - 56 IS - 9 SP - 5845 EP - 5867 PB - Springer AN - OPUS4-51946 LA - eng AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - JOUR A1 - Sprengel, Maximilian A1 - Ulbricht, Alexander A1 - Evans, Alexander A1 - Kromm, Arne A1 - Sommer, Konstantin A1 - Werner, Tiago A1 - Kelleher, J. A1 - Bruno, Giovanni A1 - Kannengießer, Thomas T1 - Towards the optimization of post-laser powder bed fusion stress-relieve treatments of stainless steel 316L JF - Metallurgical and materials transactions A N2 - This study reports on the stress relaxation potential of stress-relieving heat treatments for laser powder bed fused 316L. The residual stress is monitored non-destructively using neutron diffraction before and after the heat treatment. Moreover, the evolution of the microstructure is analysed using scanning electron microscopy. The results show, that a strong relaxation of the residual stress is obtained when applying a heat treatment temperature at 900°C. However, the loss of the cellular substructure needs to be considered when applying this heat treatment strategy. KW - Residual stress KW - Additive manufacturing KW - Neutron diffraction KW - Projekt AGIL - Alterung additiv gefertigter metallischer Materialien und Komponenten PY - 2021 UR - https://nbn-resolving.org/urn:nbn:de:kobv:b43-536045 DO - https://doi.org/10.1007/s11661-021-06472-6 SN - 1543-1940 VL - 52 IS - 12 SP - 5342 EP - 5356 PB - Springer CY - Boston AN - OPUS4-53604 LA - eng AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - JOUR A1 - Ávila Calderón, Luis Alexander A1 - Rehmer, Birgit A1 - Schriever, Sina A1 - Ulbricht, Alexander A1 - Agudo Jácome, Leonardo A1 - Sommer, Konstantin A1 - Mohr, Gunther A1 - Skrotzki, Birgit A1 - Evans, Alexander T1 - Creep and creep damage behavior of stainless steel 316L manufactured by laser powder bed fusion JF - Materials Science and Engineering: A N2 - This study presents a thorough characterization of the creep properties of austenitic stainless steel 316L produced by laser powder bed fusion (LPBF 316L) contributing to the sparse available data to date. Experimental results (mechanical tests, microscopy, X-ray computed tomography) concerning the creep deformation and damage mechanisms are presented and discussed. The tested LPBF material exhibits a low defect population, which allows for the isolation and improved understanding of the effect of other typical aspects of an LPBF microstructure on the creep behavior. As a benchmark to assess the material properties of the LPBF 316L, a conventionally manufactured variant of 316L was also tested. To characterize the creep properties, hot tensile tests and constant force creep tests at 600 °C and 650 °C are performed. The creep stress exponents of the LPBF material are smaller than that of the conventional variant. The primary and secondary creep stages and the times to rupture of the LPBF material are shorter than the hot rolled 316L. Overall the creep damage is more extensive in the LPBF material. The creep damage of the LPBF material is overall mainly intergranular. It is presumably caused and accelerated by both the appearance of precipitates at the grain boundaries and the unfavorable orientation of the grain boundaries. Neither the melt pool boundaries nor entrapped gas pores show a significant influence on the creep damage mechanism. KW - 316L KW - Laser Powder Bed Fusion (LPBF) KW - Creep behavior KW - Additive Manufacturing KW - AGIL PY - 2022 UR - https://nbn-resolving.org/urn:nbn:de:kobv:b43-539373 DO - https://doi.org/10.1016/j.msea.2021.142223 SN - 0921-5093 VL - 830 SP - 142223 PB - Elsevier B.V. AN - OPUS4-53937 LA - eng AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - JOUR A1 - Silvestroni, L. A1 - Kupsch, Andreas A1 - Müller, B. R. A1 - Ulbricht, Alexander A1 - Wieder, Frank A1 - Fritsch, Tobias A1 - Sciti, D. A1 - Bruno, Giovanni T1 - Determination of short carbon fiber orientation in zirconium diboride ceramic matrix composites JF - Journal of the European Ceramic Society N2 - In fiber-reinforced components, the fiber alignment and orientation have paramount influence on the thermomechanical properties of the resulting composite, for both short and continuous fiber. Here we present the case of an ultra-refractory matrix intended for extreme environment applications, ZrB2, reinforced with 20 vol% and 50 vol% short carbon fibers. In both cases, fibers tend to align perpendicular to the uniaxial pressure applied during shaping and sintering of a pellet, although the fiber tilt across the pellet thickness is difficult to determine. Moreover, for high volume fractions of reinforcement, the spatial distribution of the fibers is heterogeneous and tends to have domains of preferential orientations. We compare the information on the fiber distribution as collected by scanning electron microscopy images, X-ray computed tomography and synchrotron X-ray refraction radiography (SXRR). The three techniques prove to be complementary. Importantly, we demonstrate that SXRR yields the most statistically significant information due to the largest field of view, yet with a sensitivity down to the nanometer, and that can be successfully applied also to heavy matrix materials, such as zirconium boride. KW - Ceramic matrix composites KW - Synchrotron X-ray refraction radiography KW - X-ray computed tomography KW - Scanning electron microscopy KW - High-temperature ceramics PY - 2024 UR - https://nbn-resolving.org/urn:nbn:de:kobv:b43-597712 DO - https://doi.org/10.1016/j.jeurceramsoc.2024.02.048 SN - 0955-2219 VL - 44 IS - 8 SP - 4853 EP - 4862 PB - Elsevier Ltd. CY - Amsterdam AN - OPUS4-59771 LA - eng AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER -