ASTM INTERNATIONAL Helping our world work better

ISBN: 978-0-8031-7686-7 Stock #: STP1620

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ASTM INTERNATIONAL Selected Technical Papers

Structural Integrity of Additive Manufactured Parts

STP 1620Editors: Nima ShamsaeiSteve DaniewiczNik Hrabe

Structural Integrity of Additive M

anufactured PartsS

hamsaei | D

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TP 1620

Stefano BerettaJess WallerMohsen Seifi

SELECTED TECHNICAL PAPERS

STP1620

Editors: Nima Shamsaei, Steve Daniewicz, Nik Hrabe, Stefano Beretta,Jess Waller, and Mohsen Seifi

Structural Integrity ofAdditive ManufacturedParts

ASTM STOCK #STP1620DOI: 10.1520/STP1620-EB

ASTM International, 100 Barr Harbor Drive, PO Box C700, West Conshohocken, PA 19428-2959Printed in the U.S.A.

Library of Congress Cataloging-in-Publication Data

Names: Shamsaei, Nima, editor. | ASTM International, issuing body.

Title: Structural integrity of additive manufactured parts / editors, Nima

Shamsaei, Steve Daniewicz, Nik Hrabe, Stefano Beretta, Jess Waller,

Mohsen Seifi.

Description: West Conshohocken, PA : ASTM International, 2020. | Series:

Selected technical papers ; STP1620 | Includes bibliographical

references. | Summary: "This compilation of Selected Technical Papers,

STP1620, Structural Integrity of Additive Manufactured Parts, contains

peer-reviewed papers that were presented at a symposium held November

6-8, 2018, in Washington, DC, USA. The symposium was sponsored by ASTM

International Committee F42 on Additive Manufacturing Technologies, with

co-sponsorship from Committees E08 on Fatigue and Fracture and E07 on

Nondestructive Testing"-- Provided by publisher.

Identifiers: LCCN 2019055470 (print) | LCCN 2019055471 (ebook) | ISBN

9780803176867 (paperback) | ISBN 9780803176874 (pdf)

Subjects: LCSH: Three-dimensional printing--Congresses. | Machine

parts--Testing--Congresses. | Machine parts--Design and

construction--Congresses.

Classification: LCC TS171.95 .S77 2020 (print) | LCC TS171.95 (ebook) |

DDC 621.9/88--dc23

LC record available at https://lccn.loc.gov/2019055470

LC ebook record available at https://lccn.loc.gov/2019055471

ISBN: 978-0-8031-7686-7

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Printed in Hanover, PA

May, 2020

Foreword

THIS COMPILATION OF Selected Technical Papers, STP1620, Structural Integrityof Additive Manufactured Parts, contains peer-reviewed papers that were presented ata symposium held November 6–8, 2018, in Washington, DC, USA. The symposiumwas sponsored by ASTM International Committee F42 on Additive ManufacturingTechnologies, with co-sponsorship from Committees E08 on Fatigue and Fractureand E07 on Nondestructive Testing.

Symposium Chairs and STP Editors:

Nima ShamsaeiAuburn UniversityAuburn, AL, USA

Steve DaniewiczThe University of Alabama

Tuscaloosa, AL, USA

Nik HrabeNational Institute of Standards and Technology

Boulder, CO, USA

Stefano BerettaPolitecnico di Milano

Milan, Italy

Jess WallerNational Aeronautics and Space Administration, HX5

Las Cruces, NM, USA

Mohsen SeifiASTM International

Washington, DC, USA

iii

Contents

Overview ix

Metal Additive Manufacturing Defect Formation and Nondestructive

Evaluation Detectability 1

Ben Dutton, Wilson Vesga, Jess Waller, Steve James, and Mohsen Seifi

Evaluation of Nondestructive Volumetric Testing Methods for

Additively Manufactured Parts 51

Anne-Françoise Obaton, Bryan Butsch, Stephen McDonough,

Ewen Carcreff, Nans Laroche, Yves Gaillard, Jared B. Tarr, Patrick Bouvet,

Rodolfo Cruz, and Alkan Donmez

NDE-Based Quality Assurance of Metal Additively Manufactured Aerospace

Parts at NASA, JAXA, and ESA 92

Jess M. Waller, Eric R. Burke, Douglas N. Wells, Charles T. Nichols,

Ana D. Brandao, Johannes Gumpinger, Martin Born, Tommaso Ghidini,

Tsuyoshi Nakagawa, Akio Koike, Masami Mitsui, and Tsuyoshi Itoh

Eddy Current Technologies for Real-Time Monitoring and Post-Process

Examination of Laser Powder Bed Fusion Process 129

Evgueni Iordanov Todorov

Nondestructive Evaluation of Additive Manufactured Parts

Using Process Compensated Resonance Testing 165

Richard A. Livings, Eric J. Biedermann, Chen Wang, Thomas Chung,

Steven James, Jess M. Waller, Scott Volk, Ajay Krishnan, and Shane Collins

Nondestructive Evaluation of Programmed Defects in

Ti-6Al-4V L-PBF ASTM E8-Compliant Dog-Bone Samples 206

Jeong K. Na, John Middendorf, Michael Lander, Jess M. Waller,

and Richard W. Rauser

v

Expression of Additive Manufacturing Surface Irregularities through

a Flaw-Based Assessment 234

Johannes Gumpinger, Ana D. Brandao, Emilie Beevers,

Thomas Rohr, Tommaso Ghidini, Stefano Beretta, and Simone Romano

Development and Testing of 316L Stainless Steel Metal Additive Manufacturing

Test Articles for Powder Bed Fusion and Directed Energy Deposition Processes 250

Jessica L. Coughlin, Trevor G. Hicks, Patrick S. Dougherty,

and Steven A. Attanasio

Effects of the Shielding Argon Gas Flow on the Mechanical and

Physical Properties of Selective Laser Melted Ti-6Al-4V Solid Material 278

Oscar A. Quintana, Nia Hightower, and Robert Rybolt

Influence of Intentionally Induced Porosity and Postprocessing Conditions

on the Mechanical Properties of Laser Powder Bed-Fused Inconel 625 294

Jean-Rene Poulin, Morgan Letenneur, Patrick Terriault, and Vladimir Brailovski

Elucidating the Impact of Processing Parameters of Additive Manufactured

Materials Using Microscale Tensile Samples 313

Michael Duffy, Salahudin Nimer, Marc Zupan, and Steven Storck

Additive Manufactured Polymer Test Coupons: Issues and Solutions 334

Rachael Andrulonis, Royal Lovingfoss, and John Tomblin

Coupon-Level Mechanical Testing for Polymer-Based Additive Manufacturing 355

Chul Y. Park, Keith E. Rupel, Chelsey E. Henry, and Upul R. Palliyaguru

Characterization of Stress Fields Near Pores and Application to Fatigue Lives 367

James C. Sobotka and R. Craig McClung

Fatigue and Fracture Behavior of Additively Manufactured Austenitic Stainless Steel 381

Chris San Marchi, Thale R. Smith, Joshua D. Sugar, and Dorian K. Balch

Fatigue Behavior of Laser Metal Deposited 17-4 PH Stainless Steel 399

Lakshmi J. Vendra, Anjani Achanta, and Eric Sullivan

Fatigue Assessment of 17-4 PH Stainless Steel Notched Specimens Made

by Direct Metal Laser Sintering 415

Filippo Berto, Ali Fatemi, Nima Shamsaei, and Seyed Mohammad Javad Razavi

A Comparison of Stress Corrosion Cracking Susceptibility in

Additively Manufactured Ti-6Al-4V for Biomedical Applications 423

Michael Roach, R. Scott Williamson, Jonathan Pegues, and Nima Shamsaei

Fatigue Properties of Additive Manufactured Ti-6Al-4V and

CoCr-Alloy Total Ankle Components 437

Dirk Scholvin, Doug Linton, David Tuttle, Ben Walters, Scott Bible,

Jesse Fleming, and Jon Moseley

vi

Primary Processing Parameter Effects on Defects and Fatigue in Alloy 718 450

Luke Sheridan, Bo Whip, and Joy Gockel

Role of Post-Fabrication Heat Treatment on the Low-Cycle Fatigue

Behavior of Electron Beam Melted Inconel 718 Superalloy 465

Thomas Wegener, Johannes Gunther, Florian Brenne, and Thomas Niendorf

An Efficient Test Method for the Quantification of Technology-Dependent

Factors Affecting the Fatigue Behavior of Metallic Additive

Manufacturing Components 484

Gianni Nicoletto

Probabilistic Computational Fatigue and Fracture Modeling of

Additive Manufactured Components 507

Robert G. Tryon, Robert McDaniels, Andrew Chern, Michael Oja,

Animesh Dey, Ibrahim Awad, and Chad Duty

Probabilistic Framework for Defect Tolerant Fatigue Assessment of

Additively Manufactured Parts Applied to a Space Component 526

Simone Romano, Stefano Beretta, Stefano Miccoli, and Michael Gschweitl

Rapid Additive Qualification Using Probabilistics (RAQUP) 540

Genghis Khan, Natarajan Chennimalai Kumar, Liping Wang,

Vipul Gupta, Voramon Dheeradhada, Tim Hanlon, Laura Dial,

and Joseph Vinciquerra

Performance Signature Qualification for Additively Manufactured Parts

under Conditions Emulating In-Service Loading 550

John G. Michopoulos, John C. Steuben, Athanasios P. Iliopoulos,

Trung Nguyen, and Nam Phan

NASA’s Efforts for the Development of Standards for Additive

Manufactured Components 573

Richard Russell

vii

Overview

To ensure the structural integrity of additively manufactured (AM) parts, it is criti-cal to establish feedstock-process-structure-property-performance relationships,particularly where these components and structures are being used in safety-criticalapplications. ASTM International (ASTM), in coordination with partners fromgovernment, industry, and academia, has organized a series of annual symposia tohelp address these needs.

The 3rd ASTM Symposium on Structural Integrity of Additive ManufacturedParts—which took place from November 6–8, 2018, in Washington, DC—wasdesigned to provide a forum for the exchange of ideas regarding the structural in-tegrity of parts fabricated using AM, with a focus on the lack of industry standardsand design principles, as well as qualification and certification challenges.

The event was co-sponsored by ASTM Committee F42 on AdditiveManufacturing Technologies, along with Committees E08 on Fatigue and Fractureand E07 on Nondestructive Testing. It was supported by the ASTM AdditiveManufacturing Center of Excellence (AM CoE), National Aeronautics and SpaceAdministration (NASA), National Institute of Standards and Technology (NIST),European Structural Integrity Society (ESIS) TC15, and the U.S. National Congressfor Theoretical and Applied Mechanics.

Approximately 250 people attended the 3-day event, representing 11 differentnations around the world. The symposium included 56 talks by experts from indus-try, government, and academia, and 3 panel discussions, which covered nonde-structive testing and the challenges of AM standardization and adoption in themedical device and aerospace industries.

The 27 selected technical papers in this collection provide an opportunity todelve more deeply into the wide variety of topics covered during the symposium.While individual papers often touch on multiple topics, the following list presentsthe major areas covered in the symposium and the papers that address each topicas their primary focus.

A significant emphasis of this symposium was on nondestructive evaluationand in situ monitoring of AM parts, and the below articles are in this category:

� Metal Additive Manufacturing Defect Formation and Nondestructive Evalu-ation (NDE) Detectability

� Evaluation of Nondestructive Volumetric Testing Methods for AdditivelyManufactured Parts

ix

� NDE-Based Quality Assurance of Metal Additively Manufactured AerospaceParts at NASA, JAXA, and ESA

� Eddy Current Technologies for Real-time Monitoring and Post Process Exam-ination of Laser Powder Bed Fusion Process

� Nondestructive Evaluation of Additive Manufactured Parts Using ProcessCompensated Resonance Testing

� Nondestructive Evaluation of Programmed Defects in Ti-6Al-4V L-PBFASTM E8-Compliant Dog-Bone Samples

As the lack of understanding and standardization to capture the structural integrity ofAM parts is still a major roadblock against the adoption of AM in load-bearing, safetycritical applications, many papers presented relating to fatigue, fracture, tensile, andcorrosion behavior of materials and parts fabricated using AM were presented. Effectsof design, process, and post-process parameters on fatigue and fracture properties aswell as process optimization to improve structural integrity of AM parts were also dis-cussed extensively. Applicability of existing mechanical test methods to AM parts andinnovative approaches to standardization were emphasized in this symposium. Thefollowing papers focus on related topics for this category:

� Expression of Additive Manufacturing Surface Irregularities through a Flaw-Based Assessment

� Development and Testing of 316L Stainless Steel Metal Additive ManufacturingTest Articles for Powder Bed Fusion and Directed Energy Deposition Processes

� Effects of the Shielding Argon Gas Flow on the Mechanical and PhysicalProperties of Selective Laser Melted Ti-6Al-4V Solid Material

� Influence of Intentionally Induced Porosity and Postprocessing Conditions onthe Mechanical Properties of Laser Powder Bed-Fused Inconel 625

� Elucidating the Impact of Processing Parameters of Additive ManufacturedMaterials Using Microscale Tensile Samples

� Additive Manufactured Polymer Test Coupons—Issues and Solutions� Coupon-Level Mechanical Testing for Polymer Based Additive Manufacturing� Characterization of Stress Fields Near Pores and Application to Fatigue Lives� Fatigue and Fracture Behavior of Additively Manufactured Austenitic Stain-

less Steel� Fatigue Behavior of Laser Metal Deposited 17-4 PH Stainless Steel� Fatigue Assessment of 17-4 PH Stainless Steel Notched Specimens Made by

Direct Metal Laser Sintering� A Comparison of Stress Corrosion Cracking Susceptibility in Additively-

Manufactured Ti-6Al-4V for Biomedical Applications� Fatigue Properties of Additive Manufactured Ti-6Al-4V and CoCr-Alloy

Total Ankle Components

x

� Primary Processing Parameter Effects on Defects and Fatigue in Alloy 718� Role of Post-Fabrication Heat Treatment on the Low-Cycle Fatigue Behavior

of Electron Beam Melted Inconel 718 Superalloy� An Efficient Test Method for the Quantification of Technology-Dependent

Factors Affecting the Fatigue Behavior of Metallic AM Components� Probabilistic Computational Fatigue and Fracture Modeling of Additive

Manufactured Components� Probabilistic Framework for Defect Tolerant Fatigue Assessment of AM Parts

Applied to a Space Component

Finally, recent advances in standardization, qualification and certification werepresented:

� Rapid Additive Qualification Using Probabilistics (RAQUP)� Performance Signature Qualification for Additively Manufactured Parts un-

der Conditions Emulating In-Service Loading� NASA’s Efforts for the Development of Standards for Additive Manufactured

Components

We would like to extend our gratitude to everyone who made this symposium pos-sible. The hard work of the authors, coauthors, our symposium co-chairs and co-editors, peer reviewers, and personnel of ASTM and its AM CoE partners, as wellas the support of NASA, NIST, ESIS TC15, and the U.S. National Congress for The-oretical and Applied Mechanics all played a major role in the success of the sympo-sium and this publication.

Nima ShamsaeiMohsen SeifiSTP Editors

xi

ASTM INTERNATIONAL Helping our world work better

ISBN: 978-0-8031-7686-7 Stock #: STP1620

www.astm.org