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Due to the advantages of Laser Powder Bed Fusion (PBF-LB), i.e., design freedom and the possibility to manufacture parts with filigree structures, and the considerable amount of knowledge available for 316L in its conventional variant, the mechanical behavior, and related microstructure-property relationships of PBF-LB/316L are increasingly subject of research. However, many aspects regarding the - application-relevant - mechanical behavior at high temperatures are not yet fully understood. Here, we present the results of an experimental study on the LCF behavior of PBF-LB/316L featuring a low defect population, which makes this study more microstructure-focused than most of the studies in the literature. The LCF tests were performed between room temperature (RT) and 600 °C. The mechanical response is characterized by strain-life curves, and hysteresis and cyclic deformation curves. The damage and deformation mechanisms are studied with X-ray computed tomography, and optical and electron microscopy. The PBF-LB/M/316L was heat treated at 450 °C for 4 h, and a hot‑rolled (HR) 316L variant with a fully recrystallized equiaxed microstructure was tested as a reference. Besides, selected investigations were performed after a subsequent heat treatment at 900 °C for 1 h. The PBF-LB/316L exhibits higher cyclic stresses than HR/316L for most of the fatigue life, especially at room temperature. At the smallest strain amplitudes, the fatigue lives of PBF-LB/M/316L are markedly shorter than in HR/316L. The main damage mechanisms are multiple cracking at slip bands (RT) and intergranular cracking (600 °C). Neither the melt pool boundaries nor the gas porosity have a significant influence on the LCF damage mechanism. The cyclic stress-strain deformation behavior of PBF-LB/M/316L features an initial hardening followed by a continuous softening. The additional heat treatment at 900 °C for 1 h led to decreased cyclic stresses, and a longer fatigue life.
The strength of age-hardenable aluminum alloys is based on the controlled formation of nm-sized precipitates, which represent obstacles to dislocation movement. Transmission electron microscopy (TEM) is generally used to identify precipitate types and orientations and to determine their size. This geometric quantification (e.g., length, diameter) is often performed by manual image analysis, which is very time consuming and sometimes poses reproducibility problems. The present work aims at the digital representation of this characterization method by proposing an automatable digital approach. Based on DF-TEM images of different precipitation states of alloy EN AW-2618A, a modularizable digital workflow is described for the quantitative analysis of precipitate dimensions. The integration of this workflow into a data pipeline concept is also presented. The semantic structuring of data allows data to be shared and reused for other applications and purposes, which enables interoperability.
Laser Powder Bed Fusion (PBF-LB/M) of AISI 316L stainless steel has gained popularity due to its exceptional capacity to produce complex geometries and hierarchical microstructures, which can increase the yield strength while maintaining good ductility. Nevertheless, owing to high thermal gradients encountered during the process, the as printed 316L stainless steel often exhibit microstructural heterogeneities and residual stresses, which can limit its performance in demanding environments. Hence, employing heat treatments which balance the reduction of residual stresses while retaining improved static strength may be beneficial in various scenarios and applications. This study investigates the impact of post-processing heat treatments on the microstructure of 316L stainless steel manufactured via PBF-LB/M, along with its correlation with micro-hardness properties. To this end, 6 different heat treatments, i.e., 450 °C for 4h, 700 °C for 1h, 700 °C for 3h, 800 °C for 1h, 800 °C for 3h, and 900 °C for 1h, were applied to different specimens and Vickers hardness measurements (HV1) were performed in all states. At 800 °C, although the cellular structure appears to be retained, there is an observable increase in cellular size. However, while treatments exceeding 900 °C indicate no significant grain growth compared to other conditions, the cellular structure is entirely dissolved, which leads to a reduced Vickers hardness. The effect of the heat treatments on other microstructural features such as grain size and morphology, melt pool boundaries (MPB), crystallographic texture, chemical segregation, dispersoids and phase stability are also discussed in the present work
The general term additive manufacturing (AM) encompasses processes that enable the production of parts in a single manufacturing step. Among these, laser powder bed fusion (PBF-LB) is one of the most commonly used to produce metal components. In essence, a laser locally melts powder particles in a powder bed layer-by-layer to incrementally build a part. As a result, this process offers immense manufacturing flexibility and superior geometric design capabilities compared to conventional processes. However, these advantages come at a cost: the localized processing inevitably induces large thermal gradients, resulting in the formation of large thermal stress during manufacturing. In the best case, residual stress remains in the final parts produced as a footprint of this thermal stress. Since residual stress is well known to exacerbate the structural integrity of components, their assessment is important in two respects. First, to optimize process parameter to minimize residual stress magnitudes. Second, to study their effect on the structural integrity of components (e.g., validation of numerical models). Therefore, a reliable experimental assessment of residual stress is an important factor for the successful application of PBF-LB. In this context, diffraction-based techniques allow the non-destructive characterization of the residual stress. In essence, lattice strain is calculated from interplanar distances by application of Braggs law. From the known lattice strain, macroscopic stress can be determined using Hooke’s law. To allow the accurate assessment of the residual stress distribution by such methods, a couple of challenges in regard of the characteristic PBF-LB microstructures need to be overcome.
This presentation highlights some of the challenges regarding the accurate assessment of residual stress in PBF-LB on the example of the Nickel-based alloy Inconel 718. The most significant influencing factors are the use of the correct diffraction elastic constants, the choice of the stress-free reference, and the consideration of the crystallographic texture. Further, it is shown that laboratory X-ray diffraction methods characterizing residual stress at the surface are biased by the inherent surface roughness. Overall, the impact of the characteristic microstructure is most significant for the selection of the correct diffraction elastic constants. In view of the localized melting and solidification, no significant gradients of the stress-free reference are observed, even though the cell-like solidification sub-structure is known to be heterogeneous on the micro-scale.
The damage mechanisms of metallic components produced by process laser powder bed fusion differ significantly from those typically observed in conventionally manufactured variants of the same alloy. This is due to the unique microstructures of additively manufactured materials. Herein, the focus is on the study of the evolution of creep damage in stainless steel 316L specimens produced by laser powder bed fusion. X-ray computed tomography is used to unravel the influence of the process-specific microstructure from the influence of the initial void distribution on creep damage mechanisms. The void distribution of two specimens tested at 600 °C and 650 °C is analyzed before a creep test, after an interruption, and after fracture. The results indicate that the formation of damage is not connected to the initial void distribution. Instead, damage accumulation at grain boundaries resulting from intergranular cracking is observed.
Laser powder bed fusion (PBF-LB/M) of metallic alloys is a layer-wise additive manufacturing process that provides significant scope for more efficient designs of components, benefiting performance and weight, leading to efficiency improvements for various sectors of industry. However, to benefit from these design freedoms, knowledge of the high produced induced residual stress and mechanical property anisotropy associated with the unique microstructures is critical. X-ray and neutron diffraction are considered the benchmark for non-destructive characterization of surface and bulk internal residual stress. The latter, characterized by the high penetration power in most engineering alloys, allows for the use of a diffraction angle close to 90° enabling a near cubic sampling volume to be specified. However, the complex microstructures of columnar growth with inherent crystallographic texture typically produced during PBF-LB/M of metallics present significant challenges to the assumptions typically required for time efficient determination of residual stress. These challenges include the selection of an appropriate set of diffraction elastic constants and a representative lattice plane suitable for residual stress analysis. In this contribution, the selection of a suitable lattice plane family for residual stress analysis is explored. Furthermore, the determination of an appropriate set of diffraction and single-crystal elastic constants depending on the underlying microstructure is addressed.
In-situ loading experiments have been performed at the Swiss Spallation Neutron Source with the main scope to study the deformation behaviour of laser powder bed fused Inconel 718. Cylindrical tensile bars have been subjected to an increasing mechanical load. At pre-defined steps, neutron diffraction data has been collected. After reaching the yield limit, unloads have been performed to study the accumulation of intergranular strain among various lattice plane families.
Self-healing polymers have been developed to improve durability and reduce costs associated with maintenance during service. The addition of thermoplastics to thermosets to produce mendable polymers appears as a promising selfhealing technique. In this study, poly (ethylene-co-methacrylic acid) (EMAA) was added to epoxy resin and the effects of EMAA addition on epoxy properties were evaluated. Specimens with two different contents of thermoplastic and particles sizes were manufactured. A two-level full factorial experimental design was used to evaluate the effect of particle size and particle content on properties of epoxy modified with addition of EMAA. Tensile tests and dynamic mechanical analysis (DMA) were used and the evaluated responses were tensile strength, modulus of elasticity, and glass transition temperature (Tg). X-ray computed tomography (XCT) was used to investigate particle size and concentration after manufacturing. It was found that the particle concentration has greater effects on stress–strain behavior of epoxy while Tg was not significantly affected by neither of the analyzed entrance variables.
Relation of craze to crack length during slow crack growth phenomena in high‐density polyethylene
(2024)
The craze‐crack mechanism occurring in high‐density polyethylene (HDPE) causing slow crack growth and environmental stress cracking is investigated in detail with respect to the relation of crack length and the related craze zone. This is essential for the understanding of the resulting features of the formed fracture surface and their interpretation in the context of the transition from crack propagation to ductile shear deformation. It turns out that an already formed craze zone does not inevitably result in formation of a propagating crack, but could also undergo ductile failure. For the examination, the full notch creep test (FNCT) was employed with a subsequent advanced fracture surface analysis that was performed using various imaging techniques: light microscopy, laser scanning microscopy, scanning electron microscopy, and X‐ray micro computed tomography scan. FNCT specimens were progressively damaged for increasing durations under standard test conditions applying Arkopal, the standard surfactant solution, and biodiesel as test media were used to analyze the stepwise growth of cracks and crazes. From considerations based on well‐established fracture mechanics approaches, a theoretical correlation between the length of the actual crack and the length of the preceding craze zone was established that could be evidenced and affirmed by FNCT fracture surface analysis. Moreover, the yield strength of a HDPE material exposed to a certain medium as detected by a classic tensile test was found to be the crucial value of true stress to induce the transition from crack propagation due to the craze‐crack mechanism to shear deformation during FNCT measurements.
Highlights
- Progress of crack formation in high‐density polyethylene is analyzed by different imaging techniques
- Determined growth rates depend on distinction between craze zone and crack
- The ratio of the present crack to the anteceding craze zone is validated theoretically
- The transition from crack propagation to ductile shear deformation is identified
- An already formed craze zone may still fail by ductile mechanisms
Es wird eine Studie zur Charakterisierung eines anisotropen Stahls vorgestellt, bei der Ultraschalluntersuchungen mit Mikrostrukturanalysen verbunden werden. Das Material weist hohe Festigkeit und Korrosionsbeständigkeit auf, zugleich ist mit anisotropen Eigenschaften die mechanischen und betrieblichen Eigenschaften beeinflussen zu rechnen. Vorläufige Ergebnisse lassen vermuten, dass weitere Untersuchungen notwendig sind, um die Fähigkeiten und Grenzen des Materials genau zu bestimmen. Es wird ein systematischer Ansatz mit Array- Prüfköpfen, Time-of-Flight Diffraction (TOFD) Technik und mikrostrukturellen Untersuchungen angewendet, um die Wechselwirkung zwischen Anisotropie und Mikrostruktur des Stahls zu analysieren. Ultraschallprüfungen mit der TOFD-Technik und in Tauchtechnik liefern Einblicke in das anisotrope Verhalten des Werkstoffes, einschließlich entsprechenden Kornorientierung, Dämpfung und Schallgeschwindigkeitsvariation. Diese Messungen führen in Verbindung mit mikrostrukturellen Analysen zu einem tieferen Verständnis des Materialverhaltens. Unser Hauptziel ist es, ein Framework zu erstellen, welches die Ultraschallantwort anisotroper Materialien mit ihren mikroskopischen Struktureigenschaften verbindet. Die vorgestellte Methodik ermöglicht eine zerstörungsfreie und zügige Bewertung der Materialintegrität, was besonders bei der Anwendung von Hochleistungsmaterialien relevant ist. Durch diesen integrativen Ansatz werden verschiedener Charakterisierungsmethoden kombiniert, um ein umfassenderes Materialverständnis zu erreichen.
This study investigates the room‐ and high‐temperature (650 °C) tensile and low‐cycle‐fatigue behavior of Inconel 718 produced by laser powder bed fusion (PBF‐LB/M) with a four‐step heat treatment and compares the results to the conventional wrought material. The microstructure after heat treatment is characterized on different length scales. Compared to the wrought variant, the elastic and yield properties are comparable at both test temperatures while tensile strength, ductility, and strain hardening capacity are lower. The fatigue life of the PBF‐LB/M variant at room temperature is slightly lower than that of the wrought material, while at 650 °C, it is vice versa. The cyclic stress response for both material variants is characterized by cyclic softening, which is more pronounced at the higher test temperature. High strain amplitudes (≥0.7%) at room temperature and especially a high testing temperature result in the formation of multiple secondary cracks at the transitions of regions comprising predominantly elongated grain morphology and columns of stacked grains with ripple patterns in the PBF‐LB/M material. This observation and pronounced crack branching and deflection indicate that the cracks are controlled by sharp micromechanical gradients and local crystallite clusters.