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Comparison of Residual Stresses in Inconel 718 Simple Parts Made by Electron Beam Melting and Direct Laser Metal Sintering

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An Erratum to this article was published on 24 February 2015

Abstract

Residual stress profiles were mapped using neutron diffraction in two simple prism builds of Inconel 718: one fabricated with electron beam melting (EBM) and the other with direct laser metal sintering. Spatially indexed stress-free cubes were obtained by electrical discharge machining (EDM) equivalent prisms of similar shape. The (311) interplanar spacings from the EDM sectioned sample were compared to the interplanar spacings calculated to fulfill stress and moment balance. We have shown that applying stress and moment balance is a necessary supplement to the measurements for the stress-free cubes with respect to accurate stress calculations in additively manufactured components. In addition, our work has shown that residual stresses in electron beam melted parts are much smaller than that of direct laser metal sintered parts most likely due to the powder preheating step in the EBM process.

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Acknowledgments

Research at ORNL’s High Flux Isotope Reactor was sponsored by the Scientific User Facilities Division, Office of Basic Energy Sciences, and U.S. Department of Energy. Research was also sponsored by the Laboratory Directed Research and Development Program of Oak Ridge National Laboratory, managed by UT-Battelle, LLC, for the U. S. Department of Energy. Research at the Manufacturing Demonstration Facility and High Temperature Materials Laboratory at ORNL was sponsored by the Vehicle Technologies Program, Office of Energy Efficiency and Renewable Energy, U.S. Department of Energy. M. Lorentz and O. Ovichinnikova acknowledge support by the Division of Chemical Sciences, Geosciences, and Biosciences, Office of Basic Energy Sciences, United States Department of Energy under Contract DE-AC05-00OR22725 with Oak Ridge National Laboratory (ORNL), managed and operated by UT-Battelle, LLC. The authors would like to thank Alex Fima at Directed Manufacturing Inc., Fredrick List III and Tom Geer at Oak Ridge National Lab and Andrew Kolbus for their contributions to this work and the samples used.

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Authors and Affiliations

  1. Chemical and Engineering Materials Division, Oak Ridge National Laboratory, One Bethel Valley Rd., P.O. Box 2008, MS 6475, Oak Ridge, TN, 37830-6475, USA

    L. M. Sochalski-Kolbus & E. A. Payzant (Engineering Materials Group Leader)

  2. Materials Science and Technology Division, Oak Ridge National Laboratory, One Bethel Valley Rd., P.O. Box 2008, Oak Ridge, TN, 37830-6430, USA

    L. M. Sochalski-Kolbus, P. A. Cornwell (Scientific Associate), T. R. Watkins (Scattering and Thermal Properties Group Leader), R. R. Dehoff (Staff Scientist) & C. Duty (Senior Staff Scientist)

  3. Manufacturing Demonstration Facility, Oak Ridge National Laboratory, One Bethel Valley Rd., P.O. Box 2008, MS 6479, Oak Ridge, TN, 37830-6479, USA

    S. S. Babu (Governor’s Chair in Advanced Manufacturing), R. R. Dehoff (Staff Scientist) & C. Duty (Senior Staff Scientist)

  4. Department of Aerospace and Biomedical Engineering, University of Tennessee, Knoxville, USA

    S. S. Babu (Governor’s Chair in Advanced Manufacturing)

  5. Chemical Sciences Division, Oak Ridge National Laboratory, One Bethel Valley Rd., P.O. Box 2008, MS 6131, Oak Ridge, TN, 37830-6131, USA

    M. Lorenz (Scientist) & O. Ovchinnikova (Staff Scientist)

  6. National Physics Laboratory, Teddington, UK

    M. Lorenz (Scientist)

Authors
  1. L. M. Sochalski-Kolbus
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  2. E. A. Payzant
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  3. P. A. Cornwell
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  4. T. R. Watkins
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  5. S. S. Babu
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  6. R. R. Dehoff
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  7. M. Lorenz
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  8. O. Ovchinnikova
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  9. C. Duty
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Corresponding author

Correspondence to L. M. Sochalski-Kolbus.

Additional information

Notice: This manuscript has been authored by UT-Battelle, LLC, under Contract No. DE-AC05-00OR22725 with the U.S. Department of Energy. The United States Government retains and the publisher, by accepting the article for publication, acknowledges that the United States Government retains a non-exclusive, paid-up, irrevocable, world-wide license to publish or reproduce the published form of this manuscript, or allow others to do so, for United States Government purposes.

Manuscript submitted June 11, 2014.

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Sochalski-Kolbus, L.M., Payzant, E.A., Cornwell, P.A. et al. Comparison of Residual Stresses in Inconel 718 Simple Parts Made by Electron Beam Melting and Direct Laser Metal Sintering. Metall Mater Trans A 46, 1419–1432 (2015). https://doi.org/10.1007/s11661-014-2722-2

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