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Process-structure-properties investigations for laser powder bed fused IN718 in the as-built condition
This data repository provides a central location for a body of work using one build of nickel-based alloy 718 (IN718) material and resulted in three different studies. The IN718 parts were manufactured by laser powder bed fusion using a range of laser energy densities (manipulation of processing variables) and orientations with respect to the build direction. The influence of processing variables on resulting grain structures, pore structures, and mechanical properties were studied in the as-built (not heat treated) condition. Some machining was completed to manufacture specific specimen geometries, while other specimens were left with rough as-built surfaces. All data associated with each of the three studies is included in this single data repository and organized into sub-folders. The three studies are briefly described below.The first study investigated the relationships among the high-cycle fatigue (HCF) life, surface roughness, and processing parameters. Standardized fatigue specimens were manufactured using 25 different sets of processing parameters by varying laser power, scan speed, layer thickness, and build orientation. Surface roughness measurements were conducted using white light interferometry; HCF life was measured; and fractography analysis was performed using scanning electron microscopy. Build orientation affected HCF life due to the relationship between build orientation and surface roughness. Increasing surface roughness decreased the fatigue life due to increasing number of surface-crack initiation sites. For a fixed build orientation, the laser-energy density, outside of the optimal range, decreased the fatigue life due to lack-of-fusion pores at low laser-energy densities and more spherical pores at high laser-energy densities.The second study investigated the effects of build orientation and laser-energy density on the pore structure, microstructure, and tensile properties. Three different build conditions were selected from the original 25 in the previous study, namely, the conditions that resulted in the worst and best fatigue lifetimes: 0° build orientation and 38 J/mm3 laser-energy density, 0° build orientation and 62 J/mm3 laser-energy density, and 60° build orientation and 62 J/mm3 laser-energy density. In terms of microstructure, all three conditions exhibited a predominantly <001> texture in the build direction, elongated grains and sub-grain boundaries. Build orientation (0° versus 60°) produced a difference in yield strength due to anisotropic grain morphology and effective grain size. The low laser-energy density specimens showed a significant decrease in all mechanical properties compared to the optimal laser-energy density specimens because the amount and size of the lack-of-fusion porosity.The third study chose to further down sample to only two materials conditions with the same laser energy density (62 J/mm3), but two build orientations (0° and 60°). The differences in processing parameters lead to subtle variations in pore networks and thus complicate the prediction of void-sensitive mechanical behaviors, including location of fracture. This study expands upon the void descriptor function (VDF), by accounting for interactions among neighboring pores and stress concentrations induced by non-spherical pores or voids. The modified VDF is evaluated against 120 computationally generated fracture simulations and six physical tensile specimens (three for each condition). The latter set of experiments, which include X-ray computed tomography measurements before and after deformation, enables evaluation against physically realistic and representative pores in AM metals. The modified VDF accurately predicts fracture location for 94 out of 120 simulated specimens. In the experimental data set, the modified VDF accurately predicts the location of fracture in four out of six specimens compared.
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AMB2025-02 Macroscale Quasi-Static Tensile Tests of PBF-L IN718
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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.
AMB2025-03 High-Cycle Rotating Bending Fatigue Tests of PBF-L Ti-6Al-4V
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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.
AM Bench 2022 Residual Elastic Strain, Residual Stress, and Part Deflection Measurements for IN718 3D Builds
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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.
Variation of Surface Topography in Laser Powder Bed Fusion Additive Manufacturing of Nickel Super Alloy 625
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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.
Effects of as-built surface with varying number of contour passes on high-cycle fatigue behavior of additively manufactured nickel alloy 718
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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.
Effects of as-built surface with varying number of contour passes on high-cycle fatigue behavior of additively manufactured nickel alloy 718
공공데이터포털
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.
AM Bench 2018 Residual Elastic Strain Measurements of 3D Additive Manufacturing Builds of IN625 Artifacts Using Neutron Diffraction and Synchrotron X-ray Diffraction
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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 .
AM Bench 2018 Residual Elastic Strain Measurements of 3D Additive Manufacturing Builds of IN625 Artifacts Using Neutron Diffraction and Synchrotron X-ray Diffraction
공공데이터포털
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 .
In Situ Thermography During Laser Powder Bed Fusion of a Nickel Superalloy 625 Artifact with Various Overhangs and Supports
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This document provides details on the experiment and associated measurement files available for download in the dataset ?In Situ Thermography During Laser Powder Bed Fusion of a Nickel Superalloy 625 Artifact with Various Overhangs and Supports.? The measurements were acquired during the fabrication of a small nickel superalloy 625 (IN625) artifact using a commercial laser powder bed fusion (LPBF) system. The artifact consists of two half-arch features with increasing degrees of overhangs, from 5° to 85°, in increments of 10°. The artifact geometry and process are controlled to ensure consistent processing along the overhang geometry, thus enabling the effect due to overhang geometry and support structures to be isolated from effects due to inter-layer scan-strategy variations that are typical in commercial LPBF processes. The measurements include high-speed thermography of each layer, from which radiant temperature, cooling rate, and melt pool length are calculated. The objective of this experiment and data dissemination is twofold. First, to provide data for the modeling community for model validation to ensure that their models are accurately accounting for the effect of overhang geometries and support structures in thermal models. The second objective is to provide fundamental insight into these effects for researchers and process designers.
Thermographic measurements of single and multiple scan tracks on nickel alloy 625 substrates with and without a powder layer in a commercial laser powder bed fusion process (an additive manufacturing technology)
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This dataset contains thermographic measurements acquired during single and multiple track scans on bare substrates and on single layers of powder. The substrates and powder are nickel alloy 625 and the experiments are performed inside a commercial laser powder bed fusion machine. There are four experiment cases: 1) a single scan track on a bare substrate, 2) a single scan track on a single hand-spread layer of powder, 3) multiple (39) scan tracks covering an area on a bare substrate, and 4) multiple (39) scan tracks solidifying a single hand-spread layer of powder. Thermographic measurements are performed using a camera system sensitive to wavelengths between 1350 nm and 1600 nm. The camera acquires frames with an integration time of 0.04 ms and a frame rate of 1800 frames per s. The camera signal and radiant temperature values based on a black body calibration are provided. True temperature is not provided because emissivity of the surfaces is unknown. This data was used to measure melt pool length and cooling rate based on radiant temperature as part of the work in: Heigel, J. C. & Lane, B. (2017). "The effect of powder on cooling rate and melt pool length measurements using in situ thermographic techniques." In Proceedings of the 2017 Annual International SFF Symposium (https://www.nist.gov/publications/effect-powder-cooling-rate-and-melt-pool-length-measurements-using-situ-thermographic)
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