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Elastic Residual Strain and Stress Measurements and Corresponding Part Deflections of 3D Additive Manufacturing Builds of IN625 AM-Bench Artifacts Using Neutron Diffraction, Synchrotron X-Ray Diffraction, and Contour Method

  • Author(s): Phan, TQ;
  • Strantza, M;
  • Hill, MR;
  • Gnaupel-Herold, TH;
  • Heigel, J;
  • D’Elia, CR;
  • DeWald, AT;
  • Clausen, B;
  • Pagan, DC;
  • Peter Ko, JY;
  • Brown, DW;
  • Levine, LE
  • et al.

One of the primary barriers for adoption of additive manufacturing (AM) has been the uncertainty in the performance of AM parts due to residual stresses/strains. The rapid heating and cooling rates from the thermal history of the laser melting process result in high residual stresses/strains that produce significant part distortion. Efforts to mitigate residual stresses using post-process heat treatments can significantly impact the microstructures of the AM part which may lead to further issues. Therefore, the ability to accurately predict the residual stresses in as-built AM parts is crucial, and rigorous benchmark measurements are needed to validate such predictions. To fill this need, the AM-Bench aims to provide high-fidelity residual stress and strain benchmark measurements in well-characterized AM bridge-shaped parts. The measurements reported here are part of the residual elastic strain benchmark challenge CHAL-AMB2018-01-RS. Residual strains and stresses in this work were measured using neutron diffraction, synchrotron X-ray diffraction, and the contour method. Part deflection measurements were performed using a coordinate measurement machine after the part was partially separated from the build plate. These independently measured results show a high degree of agreement between the different techniques.

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