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Synchrotron Investigations of cracks in parts produced by laser powder bed fusion additive manufacturing

Reference number
Coordinator SWERIM AB - Material- och Processutveckling
Funding from Vinnova SEK 498 000
Project duration February 2020 - December 2021
Status Ongoing
Venture Research infrastructure - utilisation and collaboration
Call Industrial pilot projects for the utilisation of neutron and photon based techniques at large-scale infrastructures - Autumn 2019

Purpose and goal

This project aims to develop methods for Additive Manufacturing (AM) industry to investigate porosities, cracks and their origins in AM components. Porosity is a critical issue in additive manufacturing of metals. In order to meet these challenges Kanthal AB seek to build knowledge and benefit from the techniques provided at large scale facilities with support from Swerim AB and RISE. X-ray diffraction (XRD) and X-ray tomography (SRµCT) will be performed to A) investigate internal residual stresses, phases and precipitations and B) quantify cracks and porosities, respectively.

Expected results and effects

In certain alloy systems components with lower porosity levels, experience cracking. The cause behind this behavior is not known today. As of today, this group of alloys cannot be manufactured by LPBF with densities high enough to perform adequately. The current solution is to perform post processing steps which are costly, increase the lead time and can cause cracks. Results from planned characterization methods using synchrotron radiation in this project will allow for identification of the cause/s of cracks, their nature and how the process parameters influence them.

Planned approach and implementation

The printed samples will be categorized based on their density, residual stresses (micro-stresses) and microstructure. A couple of samples from each category will be prepared for synchrotron investigations. Residual stresses, segregation and precipitations can induce cracks in metallic materials. A combination of characterization methods using synchrotron radiation will be performed in this project to identify the cause/s of cracks, their nature and how the process parameters influence them. For volumetric quantification of the pores and cracks, SRµCT will be performed.

The project description has been provided by the project members themselves and the text has not been looked at by our editors.

Last updated 30 August 2021

Reference number 2019-05287

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