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A characterization method for mechanical properties of metal powder bed fusion parts

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Abstract

The main objective of this research is to develop a characterization method for parts fabricated in metal powder bed fusion (PBF) processes, a type of additive manufacturing (AM) process. To characterize conventionally manufactured parts, many methods and standards are available, while no comprehensive standards or methods are available for AM parts. In this paper, a mechanical property characterization method is proposed that involves statistical analysis to select sample sizes and test coupon design considerations for metal printing, printing parameters, and applicability of existing testing standards for metal PBF, in addition to several mechanical properties. As proof of concept for the proposed characterization method, material and mechanical property characterization of the metal printed (EOS M280) EOS maraging steel grade 300 material is presented along with selected sample lots and relative errors. The characterization method presented in this paper is applicable to any metal AM process.

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Abbreviations

A, B:

Specimen notation for printed and heat-treated samples, respectively

DED:

Directed energy deposition

e :

Maximum acceptable sampling error, also called allowable relative error

S :

Maximum acceptable difference between the true and sample means

n :

Number of data points

PBF:

Powder bed fusion

σ :

Standard deviation

X :

Data from test results

\( \overline{X} \) :

The mean of the data

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Acknowledgments

The authors would like to thank the funding agency, NAMIC (National Additive Manufacturing and Innovation Center) through grant 2017295, partner ST Engineering Land Systems, Singapore, for their in-kind contributions. Authors acknowledge the efforts of Senior Specialist Mr. Kai Lee, Digital Manufacturing and Design Centre, SUTD, Singapore, for assistance with specimen fabrication and testing.

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Authors and Affiliations

  1. Digital Manufacturing and Design Centre, Singapore University of Technology and Design, Singapore, 487372, Singapore

    Nandhini Raju, Samyeon Kim & David W. Rosen

  2. School of Mechanical Engineering, Georgia Institute of Technology, Atlanta, GA, 30332, USA

    David W. Rosen

Authors
  1. Nandhini Raju
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  2. Samyeon Kim
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  3. David W. Rosen
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Correspondence to David W. Rosen.

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Raju, N., Kim, S. & Rosen, D.W. A characterization method for mechanical properties of metal powder bed fusion parts. Int J Adv Manuf Technol 108, 1189–1201 (2020). https://doi.org/10.1007/s00170-020-05298-7

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