Accelerated Testing in AM: High-temperature Performance, Low-cost Solutions

The adoption of additive manufacturing (AM) for applications in extreme environments is rapidly accelerating, accompanied by the demand for customized materials with tailored properties. Often this need is driven by a desire to operate at high temperature. However, traditional elevated temperature testing methods often present significant challenges, including the need for large material volumes, expensive equipment, and lengthy testing times. This hinders the iterative development process, limiting the rapid optimization of alloys and build conditions.

This presentation will explore the application of profilometry-based indentation plastometry (PIP) at elevated temperatures as a powerful tool for rapid material characterization. With this technique, it is possible to efficiently assess mechanical properties, such as yield strength and ultimate tensile strength, under high-temperature conditions.

Case studies will be presented on collaborations with NASA, comparing conventional and novel compositions of additively manufactured nickel-based alloys, as well as next-generation aluminum-based alloys, designed to surpass the performance limitations of traditional AlSi10Mg alloys. The results will demonstrate the effectiveness of profilometry-based indentation plastometry in providing valuable insights into material behavior, enabling accelerated development cycles and facilitating the adoption of AM in demanding applications.