Origination of Defects in Powder Bed Fusion Additive Manufacturing (17-RD-923)

While the technologies involved in additive manufacturing of metallic components continue to mature, there are still many barriers to surpass before the promise of the manufacturing method is fully realized. At the front of the list of barriers is developing a better understanding of the origination of defects and how microstructures evolve throughout the process. To that end, UES, Inc. has assembled a team consisting of North Carolina State University and CalRAM, Inc. to investigate the role of process parameters and part orientation on part quality through coupling experimental characterization and process simulation. We propose to design a component with complex features which resemble a heat exchanger, manufacture multiple parts using electron-beam powder bed fusion additive manufacturing, characterize and quantify the microstructure and defects, and couple the experimental results to a thermomechanical model. By integrating a parametric study on process parameters, rapid characterization, and simulation we aim develop a toolset for designers and manufacturers that will increase first part yield and help streamline the qualification process.