High Throughput Testing of Additive Manufacturing
Navy STTR 2018.A - Topic N18A-T028 ONR - Mr. Steve Sullivan - steven.sullivan@navy.mil Opens: January 8, 2018 - Closes: February 7, 2018 (8:00 PM ET)
TECHNOLOGY
AREA(S): Materials/Processes ACQUISITION
PROGRAM: Enterprise Platform Enabler (EPE)-17-03 Quality Metal Additive
Manufacturing (Quality Made). OBJECTIVE:
Develop, optimize, and demonstrate use of high throughput mechanical testing at
key length scales to inform computational tools and rapidly determine effects
of defects for additive manufacturing (AM). High throughput testing must focus
on static and dynamic material properties equivalent to conventional American
Society for Testing Materials (ASTM) tests. DESCRIPTION:
There have been significant advancements in computational modeling tools to
correlate and explore the interactions of microstructure and material
properties. In order to validate these computational tools, static and dynamic
tests are used to provide statistically relevant mechanical properties across
the material composition and processing space. In AM, this information is
necessary to inform computational tools being developed. Conventional tensile
and fatigue tests are time-consuming to fabricate and test for the desired compositional
and process windows. Similarly understanding the effects of defects in AM
requires testing at key length scales based on critical geometric features.
New techniques for high throughput testing can inform computational models and
key acceptance criteria for non-destructive inspection. PHASE
I: Define and develop a concept/approach for high throughput testing of metal
AM to probe micro- and meso-scale features such as voids, porosity, and lack of
fusion. Key features may be on the order of 50-100um and test specimen sizes
should be greater than 200um in thickness based on current MIL-STD-2035A
criteria. The concept must provide a 10x throughput improvement over
conventional ASTM E8 and ASTM E466 tests. This may include design or
adaptation of existing techniques or equipment to support testing materials
directly from a build plate and measurement of key load/displacements. This
topic will also consider methods for preparing (or extracting) test coupons
with well characterized isolated defects for multi-length, scale model
development. If awarded the Phase I option, the small business will
demonstrate the feasibility of the proposed concept/approach. Develop a Phase
II plan. PHASE
II: Based on Phase I results, develop, demonstrate, and validate the proposed
high throughput test apparatus for tensile testing. Rapid defect
characterization methods, before and after destructive mechanical testing,
should also be considered in specimen preparation and testing for testing
validation. The apparatus will be investigated for use in fatigue testing. It
is recommended that the performer work with bulk material vendors/Original
Equipment Manufacturers (OEMs) to facilitate transition for Phase III. PHASE
III DUAL USE APPLICATIONS: Phase III will transition optimized high throughput
testing techniques to commercial suppliers through bulk material vendors, OEMs,
or other partnering agreement(s). Commercialization of this technology may be
through new material discovery or rapid process development. Phase III will
demonstrate the technology to Warfare Centers and other DoD
production/maintenance facilities. REFERENCES: 1.
ASTM E8, Standard Test Methods for Tension Testing of Metallic Materials, https://www.astm.org/Standards/E8.htm 2.
ASTM E466, Standard Practice for Conducting Force Controlled Constant Amplitude
Axial Fatigue Tests of Metallic Materials, https://www.bsbedge.com/astm/astme466-standard 3.
MIL-STD-2035A, Department of Defense Test Method: Nondestructive Testing
Acceptance Criteria (15 May 1995), http://everyspec.com/MIL-STD/MIL-STD-2000-2999/MIL-STD-2035A_6636/ 4.
Slotwinski, John A., Garboczi, Edward J. and Hebenstreit, Keith M. “Porosity
Measurements and Analysis for Metal Additive Manufacturing Process Control.”
Journal of Research of the National Institute of Standards and Technology, Vol.
119 (2014), http://nvlpubs.nist.gov/nistpubs/jres/119/jres.119.019.pdf 5.
Lee, Jaewon. “Failure Mechanism of Laser Welds in Lap-Shear Specimens of a
High Strength Low Alloy Steel.” J. Pressure Vessel Technology 134(6), 061402
(Oct 18, 2012), http://pressurevesseltech.asmedigitalcollection.asme.org/article.aspx?articleid=1661606 KEYWORDS:
Additive Manufacturing; High Throughput Testing; Tensile; Fatigue; Effects of
Defects; Non-destructive Inspection
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