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The combination of microstructural data with other experimental techniques and with modeling is paramount, if we want to extract the maximum amount of information on porous material properties. In particular, quantitative image analysis, statistical approaches, direct discretization of tomographic reconstructions represent concrete possibilities to extend the power of the tomographic 3D representation to insights into the material and component performance. I will show a few examples of possible use of X-ray tomographic data for quantitative assessment of porosity in ceramics.
Moreover, I will show how not-so-novel 2D characterization techniques, based X-ray refraction, can allow a great deal of insights in the damage evolution in microcracked (and porous) ceramics. I will show how X-ray refraction can detect objects (e.g. microcracks) below its own spatial resolution.
Finally, I will discuss the link between the microstructural findings and the mechanical properties of porous microcracked ceramics.
The combination of microstructural data with other experimental techniques and with modeling is paramount, if we want to extract the maximum amount of information on porous material properties. In particular, quantitative image analysis, statistical approaches, direct discretization of tomographic reconstructions represent concrete possibilities to extend the power of the tomographic 3D representation to insights into the material and component performance. I will show a few examples of possible use of X-ray tomographic data for quantitative assessment of porosity in ceramics.
Moreover, I will show how not-so-novel 2D characterization techniques, based X-ray refraction, can allow a great deal of insights in the damage evolution in microcracked (and porous) ceramics. I will show how X-ray refraction can detect objects (e.g. microcracks) below its own spatial resolution.
Finally, I will discuss the link between the microstructural findings and the mechanical properties of porous microcracked ceramics.
A paradigm shift in the description of creep in metals can only occur through multi-scale imaging
(2022)
The description of creep in metals has reached a high level of complexity; fine details are revealed by all sorts of characterization techniques and different theoretical models. However, to date virtually no fully microstructure-driven quantitative description of the phenomenon is available. This has brought to interesting inconsistencies; the classic description of (secondary) creep rests on the so-called power law, which however: a- has a pre-factor spanning over 10 orders of magnitude; b- has different reported exponents for the same material; c- has no explanation for the values of such exponents.
Recently, a novel description (the so-called Solid State Transformation Creep (SSTC) Model) has been proposed to tackle the problem under a different light. The model has two remarkable features: 1- it describes creep as the accumulation of elementary strains due to dislocation motion; 2- it predicates that creep is proceeding by the evolution of a fractal arrangement of dislocations. Such description, however, needs a great deal of corroborating evidence, and indeed, is still incomplete.
To date, we have been able to observe and somehow quantify the fractal arrangement of microstructures through Transmission Electron Microscopy (TEM), observe the accumulation of dislocations at grain boundaries by EBSD-KAM (Electron Back-Scattered Diffraction-Kernel Angular Misorientation) analysis, quantify the kinetic character (solid state transformation) of experimental creep curves, and estimate the sub-grain size of the fractal microstructure through X-ray refraction techniques. All pieces of the mosaic seem to yield a consistent picture: we seem being on the right path to reconstruct the whole elephant by probing single parts of it. What is still missing is the bond between the various scales of investigation.
Having been introduced almost two decades ago, Additive Manufacturing (AM) of metals has become industrially viable for a large variety of applications, including aerospace, automotive and medicine. Powder bed techniques such as Selective Laser Melting (SLM) based on layer-by-layer deposition and laser melt enable numerous degrees of freedom for the geometrical design. Developing during the manufacturing process, residual stresses may limit the application of SLM parts by reducing the load bearing capacity as well as induce unwanted distortion depending on the boundary conditions specified in manufacturing.
The residual stress distribution in IN718 elongated prisms produced by SLM was studied non-destructively by means of neutron (bulk) and laboratory X-ray (surface) diffraction. The samples with different scanning strategies, i.e. hatching length, were measured in as-built condition (on a build plate) and after removal from the build plate.
While surface stress fields seem constant for AB condition, X-ray diffraction shows stress gradients along the hatch direction in the RE condition. The stress profiles correlate with the distortion maps obtained by tactile probe measurements.
Neutron diffraction shows bulk stress gradients for all principal components along the main sample directions. We correlate the observed stress patterns with the hatch length, i.e. with its effect on temperature gradients and heat flow. The bulk stress gradients partially disappear after removal from the baseplate.
Together with surface scan utilizing a coordinate-measuring machine (CMM), it is possible to link the stress release to the sample distortion.
We finally propose an explanation of those stress profiles based on the deposition strategy.
Ein Nachteil der klassischen Durchstrahlungstechnik mit Röntgenstrahlen ist die, in der Abbildung des Untersuchungsobjektes, fehlende Tiefeninformation. Die Anwendung von radiografischen Verfahren, die das Objekt unter zwei oder mehreren Winkelpositionen durchstrahlen, erlauben die Rekonstruktion räumlicher Abbildungen. Dazu zählen Stereoradiografie, Translations- und Rotationslaminographie. Bei der Computertomographie erfolgt die Durchstrahlung unter einem Winkelbereich von 180° oder 360°. Die dabei aufgenommenen Projektionen werden anschließend durch Anwendung der Fourier Transformation und der gefilterten Rückprojektion zu einem 3D-Bilddatensatz rekonstruiert. Verschiedene systembedingte Artefakte, die das Ergebnis negativ beeinflussen können, lassen sich durch geeignete Meß- und Rekonstruktionsparameter, sowie einer nachfolgende Bildverarbeitung eliminieren oder reduzieren.
In this talk the basics of X-ray computed tomography (XCT) are presented, together with a description of complementary techniques such as Laminography and Stereoradiography.
A overview of the common reconstruction approach and of the artifacts that can occur during reconstruction or acquisition of XCT images is also given.
Finally, application examples in the field of construction materials are given, whereby several experimental techniques (Region of Interest Approach) and data analysis methods (e.g. Digital volume correlation) are explained. Such techniques and algorithms are used to extract quantitative information from ex- and in-situ experiments.
In Additive Manufacturing everybody is talking about Free Form, Unconventional Design, Re-thinking Components, “Think out of the box”.
However, there are a few outstanding question: a) What are the material properties ? They certainly differ from literature values for conventional materials; b) How about the microstructure? It is different from conventional materials. Does it stay so with ageing? How does it form? c) Do we properly take residual stress into account? We often blame them for our ignorance about failure scenarios. d) Do we apply tailored heat treatments? Very often, we follow conventional schedules…
This talk describes the summary of the efforts carried out within the BAM Project AGIL.
At BAM, we aimed to thoroughly investigate the microstructure and how it evolves as a function of load and temperature (service), to determine the material properties after different process and service conditions, to properly determine residual stress and the way it impacts mechanical properties and component performance, to properly quantify the impact of (unavoidable?) defects, and to determine heat treatments tailored to the process-specific material (stress relieve, microstructure homogenization etc.).
The Project AGIL was and is intimately coupled with the project ProMoAM, dealing with online monitoring of AM processes.
Avoid living dangerously: non-destructive characterization of AM parts from powder to end-of-life
(2019)
The freeform and the revolutionary design possibilities offered by additive manufacturing have skyrocketed the amount of optimization studies in the realm of engineering, and metallic additive manufactured parts are becoming a reality in industry.
Not surprisingly, this has not been paralleled by a similar enthusiastic wave in the realm of materials science, and still very little is known about AM materials properties. This has the consequence that, typically, conventional materials properties are still used in design and even in simulations.
lt is necessary to dig a lot deeper than at present, in order to understand these new materials classes, and in particular their microstructure and their intemal stresses, largely different from their cast or wrought companions.
The overview of the activity of Federal Institute for Material Research and Testing (BAM, Belin, Germany) in the field of additively manufacturing material characterization will be presented. The research of our group is focused on the 3D imaging of AM materials by means of X-ray Computed Tomography at the lab and at synchrotron, and the residual stress characterization by diffraction (nondestructive technique). Also, two successful research project in collaboration with CAM2, Sweden are presented.