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The understanding of process-microstructure-property-performance (PMPP) relationships in additive manufacturing (AM) of metals is highly necessary to achieve wide-spread industrial application and replace conventionally manufactured parts, especially regarding safety-relevant applications. To achieve this understanding, reliable data and knowledge regarding material’s microstructure-property relationships (e.g. the role of defects) is needed, since it represents the base for future more targeted process optimizations and more reliable calculations of performance. However, producing reliable material data and assessing the AM material behaviour is not an easy task: big challenges are e.g. the actual lack of standard testing methods for AM materials and the occasional difficulties in finding one-to-one comparable material data for the conventional counterpart.
This work aims to contribute to end this lack of reliable material data and knowledge for the low cycle fatigue behaviour of the most used titanium alloy in aerospace applications (Ti-6Al-4V). For this purpose, two sets of test specimens were investigated. The first set was manufactured from cylindrical rods produced by an optimized DED-L process and the second was manufactured from a hot formed round bar. The test specimens were cyclically loaded until failure in the low-cycle-fatigue (LCF) regime. The tests were carried out according to ISO 12106 between 0.3 to 1.0 % axial strain amplitude from room temperature up to 400°C. The LCF behaviour is described and compared between materials and with literature values based on cyclic deformation curves and strain-based fatigue life curves. Besides, the parameters of Manson-Coffin-Basquin relationship were calculated. The microstructures (initial and after failure) and fracture surfaces were comparative characterized. Thereby, the focus lied on understanding the role of grain morphology and defects on the failure mechanisms and fatigue lifetimes. For this latter characterization, optical microscopy (OM), scanning electron microscopy (SEM) and micro computed tomography (µCT) were used.
Eine kritische Aufgabe im Rahmen der Etablierung von Prozess-Struktur-Eigenschafts-Performance-Beziehungen bei der additiven Fertigung (AM) von Metallen ist die Ermittlung von zuverlässigen und gut dokumentierten Kennwerten zum Materialverhalten sowie das Schaffen von Wissen über die Struktur-Eigenschafts-Korrelation. Schließlich ist dies die Grundlage für die Entwicklung gezielterer Prozessoptimierungen und zuverlässigerer Lebensdauer-Vorhersagen. In diesem Zusammenhang zielt dieser Beitrag darauf ab, Daten und Erkenntnisse über das Kriechverhalten des austenitischen Edelstahls 316L zu liefern, der mittels Laser-Powder-Bed-Fusion (L-PBF) hergestellt wird. Um dieses Ziel zu erreichen, wurden Proben aus konventionellem warmgewalztem sowie AM-Material gemäß den bestehenden Normen für konventionelles Material geprüft und vor und nach dem Versagen mikrostrukturell charakterisiert. Die Probekörper wurden aus einzelnen Blöcken des AM-Materials gefertigt. Die Blöcke wurden mit einer Standard-Scan- und Aufbaustrategie hergestellt und anschließend wärmebehandelt. Das Kriechverhalten wird anhand der Kriechlebensdauer und ausgewählter Kriechkurven und Kennwerte beschrieben und vergleichend bewertet. Der Einfluss von Defekten und Mikrostruktur auf das Materialverhalten wird anhand von zerstörenden und zerstörungsfreien Auswertungen an ausgewählten Proben analysiert. Der AM-Werkstoff zeigt kürzere Kriechlebensdauern, erreicht das sekundäre Kriechstadium deutlich schneller und bei geringerer Dehnung und weist eine geringere Kriechduktilität im Vergleich zu seinem konventionellen Gegenstück auf. Das Kriechschädigungsverhalten des AM-Werkstoffs ist eher mikrostruktur- als defektgesteuert und ist durch die Bildung intergranularer Kriechrisse gekennzeichnet. Als kritische Merkmale werden die Versetzungsdichte sowie die Versprödung der Korngrenzen identifiziert. Die Mikro-Computertomographie (µCT) erweist sich als Alternative zur Metallographie, um die Kriechschädigung zu analysieren.
Creep and fracture behavior of conventionally and additively manufactured stainless steel 316L
(2020)
A critical task within the frame of establishing process-structure-property-performance relationships in additive manufacturing (AM) of metals is producing reliable and well-documented material behavior’s data and knowledge regarding the structure-property correlation, including the role of defects. After all, it represents the basis for developing more targeted process optimizations and more reliable predictions of performance in the future. Within this context, this contribution aims to close the actual gap of limited historical data and knowledge concerning the creep behavior of the widely used austenitic stainless steel 316L, manufactured by Laser-Powder-Bed-Fusion (L-PBF). To address this objective, specimens from conventional hot-rolled and AM material were tested under application-relevant conditions according to existing standards for conventional material, and microstructurally characterized before and after failure. The test specimens were machined from single blocks from the AM material. The blocks were manufactured using a standard scan and build-up strategy and were subsequently heat-treated. The creep behavior is described and comparatively assessed based on the creep lifetime and selected creep curves and characteristic values. The effect of defects and microstructure on the material’s behavior is analyzed based on destructive and non-destructive evaluations on selected specimens. The AM material shows shorter creep lives, reaches the secondary creep stage much faster and at a lower strain, and features lower creep ductility compared to its conventional counterpart. The creep damage behavior of the AM material is more microstructure than defect controlled and is characterized by the formation and accumulation of single intergranular damage along the whole volume. Critical features identified are the grain morphology and the grain-boundary as well as the dislocation’s density. Micro-computed tomography (µCT) proves to be an alternative to metallography to analyze the creep damage.
The understanding of dynamic processes in Li-metal batteries is an important consideration to enable the full capacity of cells to be utilised. These processes, however, are generally not directly observable using X-ray techniques due to the low attenuation of Li; and are challenging to visualise using neutron imaging due to the low temporal resolution of the technique. In this work, complementary X-ray and neutron imaging are combined to track the dynamics of Li within a primary Li/SOCl2 cell. The temporal challenges posed by neutron imaging are overcome using the golden ratio imaging method which enables the identification of Li diffusion in operando. This combination of techniques has enabled an improved understanding of the processes which limit rate performance in Li/SOCl2 cells and may be applied beyond this chemistry to other Li-metal cells.
The ability to track electrode degradation, both spatially and temporally, is fundamental to understand performance loss during operation of lithium batteries. X-ray computed tomography can be used to follow structural and morphological changes in electrodes; however, the direct detection of electrochemical processes related to metallic lithium is difficult due to the low sensitivity to the element. In this work, 4-dimensional neutron computed tomography, which shows high contrast for lithium, is used to directly quantify the lithium diffusion process in spirally wound Li/SOCl2 primary cells. The neutron dataset enables the quantification of the lithium transport from the anode and the accumulation inside the SOCl2 cathode to be locally resolved. Complementarity between the collected neutron and X-ray computed tomographies is shown and by applying both methods in concert we have observed lithium diffusion blocking by the LiCl protection layer and identified all cell components which are difficult to distinguish using one of the methods alone.
Using spatial and temporal shaping of laser-induced diffuse thermal wave fields in thermography
(2020)
The diffuse nature of thermal waves is a fun-damental limitation in thermographic nonde-structive testing. In our studies we investigated different approaches by shaping the thermal wave fields which result from heating. We have used high-power laser sources to heat metallic samples. Using these spatial and temporal shaping techniques leads to a higher detection sensitivity in our measurements with the infra-red camera. In this contribution we show our implementation of shaping laser-induced diffuse thermal wave fields and the effect on the defect reconstruction quality.
To assess the clinical course of a sheep stifle joint model for osteochondral (OC) defects, medial femoral condyles (MFC) were exposed without patella luxation using medial parapatellar skin (3–4 cm) and deep incisions (2–3 cm). Two defects (7 mm diameter; 10 mm depth; OC punch) were left empty or refilled with osteochondral autologous transplantation cylinders (OATS) and explanted after six weeks. Incision-to-suture time, anesthesia time, and postoperative wound or impairment scores were compared to those in sham-operated animals. Implant performance was assessed by X-ray, micro-computed tomography, histology, and immunohistology (collagens 1, 2; aggrecan). There were no surgery-related infections or patellar luxations. Operation, anesthesia, and time to complete stand were short (0.5, 1.4, and 1.5 h, respectively). The wound trauma score was low (0.4 of maximally 4; day 7). Empty-defect and OATS animals reached an impairment score of 0 significantly later than sham animals (7.4 and 4.0 days, respectively, versus 1.5 days). Empty defects showed incomplete healing and dedifferentiation/heterotopic differentiation; OATS-filled defects displayed advanced bone healing with remaining cartilage gaps and orthotopic expression of bone and cartilage markers. Minimally-invasive, medial parapatellar surgery of OC defects on the sheep MFC allows rapid and low-trauma recovery and appears well-suited for implant testing.
By means of a small-scale truss bridge, the ability of the Measurement- and Model-based Structural Analysis to detect and localise damage was examined in. Although there was no noteworthy difficulty in detecting damage, it turned out that damage localisation responds sensitively to systematic influences, i.e. non-modelled properties of the mechanical model. Therefore, another experiment is being conducted to re-examine the Measurement- and Model-based Structural Analysis. For this purpose, the bending test is carried out as it has been already theoretically respectively numerically discussed in. In this attempt, the systematic influences such as residual stress are kept as low as possible.
The ever more ambitious strategic goals of meeting the requirements in ensuring technical safety and security of civil structures have resulted in flourishing development of innovative structural health monitoring (SHM) technologies for early damage diagnosis and prognosis. At the same time, implementing SHM systems provides tangible economic benefits derived from lower life-cycle costs associated with reduction in the maintenance, repair and insurance expenses. Due to the large size and harsh environmental conditions common to most civil structures, the broad range of favorable physical-mechanical properties of POFs allow for customized monitoring solutions for a wide variety of applications.
In addition to common SHM-related advantages of optical fibers including their electromagnetic immunity, small size, lightweight as well as spark-free and non-conductive characteristics, POFs offer better bending and fracture resistance then their glass-counterparts. Particularly, the improved robustness of POFs, their ease of handling, low Young’s Modulus and high elastic limit of 10% compared to 1% in silica glass [1] are relevant to practical applications. Depending on the composition, dopants, drawing process and geometry [2], strain measurement up to 45% [3] or even above 100% [4,5] has been demonstrated with standard POFs. Therefore, the dominant market expected for POF sensors includes monitoring of high-strain-rate deformations in earthwork structures, crack detection in concrete and masonry structures [6] or overstressing in high-rise steel structures exposed to moisture, corrosion, leakage, fatigue, vibration, fire, overflow, earthquake and intentional damage. For fracture monitoring within concrete structures, the sensory usage of POFs becomes especially favorable since the extremely alkaline environment of concrete mixtures is well known to be corrosive to standard silica glass optical fibers (GOFs) [1,7].
Most of advanced distributed sensing techniques are commonly based on Rayleigh backscatter reflectometry using commercially available multimode (MM) POFs. Such typical MM POFs range from a step-index (SI) poly(methyl methacrylate) (PMMA) POF having a core diameter of 1 mm to a low-loss graded-index (GI) perfluorinated (PF) POF based on poly(perfluorobutenyl-vinylether) also known as CYTOP [8] with a 50 µm core diameter. The relatively low optical attenuation value of 30 dB/km at 1.3 µm [9,10] makes PFGI POFs also interesting for distributed Brillouin sensing [11-14]. Compared to GOFs, PFGI POFs offer better potential for temperature measurement and have comparably low theoretical attenuation limit [15]. Therefore, POF-based distributed Brillouin sensing is expected to play an important role in the future of SHM, especially at high-strain ranges. The significance of the Brillouin measurment technique can be also enhanced by further development of the single-mode (SM) POFs which are still subject of research and are used for coherent detection techniques [6]. Furthermore, SM PMMA POFs have been characterized in a Mach-Zehnder interferometer setup for strain values up to 15.8% [16,17].
The current development of SM perfluorinated and microstructured POFs (mPOFs) represents an immense promise for quasi-distributed dynamic measurement at high strain levels based on fiber Bragg grating (FBG) technology. While SM mPOFs with optical losses of about 1 dB/m can be fabricated [6], the SM PF POFs presented by Zhou et al. feature low attenuation of even less than 0.2 dB/m in the wavelength range of 1.41 µm to 1.55 µm [18]. At the same time, the SM PF POFs have the potential for improved thermal stability compared to their PMMA counterparts [19].
This whole chapter provides a comprehensive overview on current POF-based sensing principles and SHM technologies, highlighting their diverse applications in civil engineering structures. In the application-related context, close attention is paid to the development of smart sensor-based geotextiles and geogrids. Such geosynthetics-integrated distributed POF sensors have proven to be a promising solution for two- or even tree-dimensional monitoring of critical high mechanical deformations in both geotechnical and masonry structures. Moreover, geosynthetics in the form of nonwoven geotextiles as well as polymer-based geogrids used as carrier materials for POF sensors enable optimized load transfer from the monitored structure to the measuring fiber without losing their original functionality. In other words, smart geosynthetics provide a cost-efficient dual solution for, on the one hand, well-established increase of structure stability and decrease of erosion effects, on the other hand, early-warning and detection capabilities in the prevention and elimination of potential hazards and lasting damages.