Abstract (from the manuscript): High cycle fatigue life of laser-powder bed fusion (L-PBF) parts depends on several factors; as-built surfaces, when present, are a particular concern. This work measures as-built L-PBF surfaces with X-ray computed tomography, and uses rotating beam fatigue (RBF) testing to measure high cycle fatigue life. Surfaces with different, but consistent, characteristics are achieved by build in vertical specimens and changing only the number of contour passes. In this way, specimens with three different levels of surface roughness are compared to standard polished specimens. The results from this show that surface roughness increases with decreasing number of contour passes, but the impact on fatigue lifetime is not trivially related. Electron microscopy and x-ray computed tomography images show multiple initiation points and complex surface topology, but that surface feature depth is not necessarily correlated to failure location. Two primary conclusions are that 1) for the case of as-built surfaces loaded in bending, one contour pass is sufficient to achieve peak as-built performance, and even zero contour passes was not statistically significantly different from two passes; 2) surface feature depth, even when measured using metal-penetrating imaging, is not strongly associated with failure location in our data. When assessing AM surfaces, more factors (e.g., grain orientation) may be required to mechanistically understand the performance implications.This dataset is comprised of four main types of data: 1. Build data, including CAD files and heat treatment logs. 2. Fatigue data, from RBF testing tabulated in the form of measured stresses and forces, and fatigue lives (cycle counts). 3. Fractography data, in the form of SEM and optical images of failure surfaces after RBF testings. 4. X-ray Computed Tomography data, comprising 3D images, associated image processing codes, and tabulated data describing the surface profiles and deepest surface notches for 6 specimens of particular interest.

Specimens from one build of laser powder bed fusion (PBF-L) titanium alloy (Ti-6Al-4V) were split equally into two heat treatment conditions. The first condition is a non-standard hot isostatic pressing (HIP) heat treatment (800 °C, 2 h, argon pressure of 200 MPa, approximately 12 °C/min cooling rate), which will be referred to as 800HIP. The second condition is the same heat treatment but in a vacuum furnace with a partial pressure of argon (75 mTorr), and will be referred to as 800VAC. All fatigue specimens were vertically oriented during PBF-L, then after post-processing was completed, the specimens were machined and polished to remove the as-built surface roughness and PBF-LB contour. Approximately 25 specimens per condition were tested in high-cycle fully reversed 4-point rotating bending fatigue (RBF, R = -1) according to ISO 1143. Calibration data given for both conditions will include: detailed build parameters, heat treatment details (time, temperature, and chamber pressure), solid chemistry, surface roughness measurements of the gauge section of fatigue specimens, strain measured in gauge section of fatigue specimens via x-ray diffraction (XRD), 2D maps of grain size and morphology via scanning electron microscopy (SEM), 2D crystallographic texture via electron backscatter diffraction (EBSD), pore size and spatial distribution via x-ray computed tomography (XCT), and quasi-static tensile properties according to ASTM E8. All fatigue data (S-N curve) for the 800HIP condition will also be given as calibration data.

This dataset provides surface height data from nickel super alloy 625 experiment samples built through laser powder bed fusion additive manufacturing. The experiment methodically varied part position and orientation relative to the build plate and recoater blade and details of the experiment and dataset are available in a Journal of Research at NIST article.

The following data files include residual elastic strain, residual stress, and part deflection results associated with the 2022 Additive Manufacturing Benchmark test series (AM Bench 2022) AMB2022-01 benchmark on laser powder bed fusion (LPBF) 3D builds of nickel-based superalloy IN718 test objects. The AM builds were performed on the NIST Additive Manufacturing Metrology Testbed (AMMT). The residual elastic strains were measured using synchrotron X-ray diffraction at the Cornell High Energy Synchrotron Source (CHESS) and neutron diffraction at the Oak Ridge National Laboratory (ORNL) High Flux Isotope Reactor (HFIR). Residual stresses were characterized using the contour method by UC Davis and Hill Engineering. Part deflection after partial cutting of the build part off the build plate was measured at NIST. Detailed descriptions of the build process parameters, scan pattern, heat treatment, and descriptions of all of the AMB2022-01 measurements are provided on the AMB2022-01 challenge description webpage (https://www.nist.gov/ambench/amb2022-01-benchmark-measurements-and-challenge-problems). Due to the time-sensitive nature of the AM Bench challenge problems, those measurements and analyses were prioritized. The challenges that this data publication address are:Residual elastic strain (CHAL-AMB2022-01-RS): Residual elastic strain components at select locations internal to the bridge structure, corresponding to synchrotron X-ray diffraction measurements. Part deflection (CHAL-AMB2022-01-PD): Deflection of the as-built (no heat treatment) bridge structure after it is partially separated from the build plate.Additional datasets that are not required for the challenges will be added soon. For updates, please check back here or at www.nist.gov/ambench.

This challenge is a follow-on from AMB2022-01 laser powder bed fusion (PBF-LB) alloy Inconel 718 in the as-built condition (no heat treatment). Eight continuum-but-miniature tensile specimens were excised from the same size legs (2.5 mm width) of one original AMB2022-01 specimen (AMB2022-718-AMMT-B7-P4). Excised tensile specimens were quasi-static uniaxially tensile tested according to ASTM E8 (strain rate 1*10-3 sec-1, 3 mm gauge length custom contact extensometer). Calibration data given includes all processing and microstructure data from AMB2022-01 (https://www.nist.gov/ambench/am-bench-2022-challenge-problems-and-measurement-results), including 3D serial sectioning electron backscatter diffraction (EBSD) data (https://doi.org/10.18434/mds2-2767). Material property data such as elastic mechanical properties are not provided.

The development of large residual elastic strains and stresses during laser powder-bed fusion (LPBF) additive manufacturing is one of the most significant barriers to widespread adoption. Accurate modeling of these strains and stresses is broadly recognized as an effective tool for mitigating these challenges, but rigorous validation data are needed. This data publication includes measurement data from diffraction-based characterizations of residual elastic strains in as-built (not heat treated) artifacts manufactured as part the the 2018 Additive Manufacturing Benchmark Series (AM Bench). Comprehensive details about AM Bench and the measurement data released in 2018 and 2022 may be found at .

The development of large residual elastic strains and stresses during laser powder-bed fusion (LPBF) additive manufacturing is one of the most significant barriers to widespread adoption. Accurate modeling of these strains and stresses is broadly recognized as an effective tool for mitigating these challenges, but rigorous validation data are needed. This data publication includes measurement data from diffraction-based characterizations of residual elastic strains in as-built (not heat treated) artifacts manufactured as part the the 2018 Additive Manufacturing Benchmark Series (AM Bench). Comprehensive details about AM Bench and the measurement data released in 2018 and 2022 may be found at .