Quantifying the Effects of Build Interruptions in LPBF for Nickel Alloy 718 and AlSi10Mg

Conference Abstract: Over the past decade, AM, specifically Laser Powder Bed Fusion (LPBF), has witnessed remarkable growth. Yet, every industry that has integrated LPBF technology confronts build interruptions due to factors such as power outages, machine failures, software/design issues, sensor triggers, and over-consumption of materials like powder or inert gas…the list goes on.
The repercussions of these interruptions on the quality and integrity of the resulting additively manufactured materials in LPBF remain an area requiring further exploration. Our study investigates the impact of build interruptions by utilizing mechanical testing, in-situ monitoring, and microscopy. For this, we simulated interruptions by printing mechanical test specimens, pausing the builds partway, and resuming until completion. Comprehensive data from in-situ monitoring systems and mechanical tests were aggregated to assess the influence of these interruptions on the ultimate tensile strength (UTS) and fatigue life.
The talk will discuss our findings for both: Nickel alloy 718 and A10SiMg as well as the resulting mechanical behavior due to the interruptions. Resulting CT scans and in-situ monitoring data will also be covered.
In conclusion, I will spotlight ongoing research at The Ohio State University's Center for Design and Manufacturing Excellence (CDME). This summary will highlight our commitment to advancing the industrialization of AM through applied research, contributing to the development of innovative processes, materials, and applications.