Additive Manufacturing Fatigue and Fracture

Description

Metal additive manufacturing (AM) is not used in fatigue and fracture critical applications despite industrial need.  The goal of this project is to enable confident use of metal AM in critical applications through: 

• Advancing metrological practice for AM-specific performance metrics encompassing the full processing-structure-properties-performance spectrum and the full AM lifecycle
• Developing process and post-process control methods to reduce material variability and improve performance
• Developing new non-destructive evaluation (NDE) techniques that are fast, inexpensive, precise, and capable of inspecting larger parts with complex geometries common in AM
• Developing a rapid qualification framework based on digital twin to reduce cost and time to production
• Developing consensus AM standards with key stakeholders and various standards development organizations

Scanning electron microscope (SEM) images of AM titanium alloy (Ti-6Al-4V) high-cycle fatigue fracture surfaces showing fatigue crack initiation at lack-of-fusion (LOF) defect (white arrow).  Also shown on the same fracture surface are entrapped gas pores.

Research HIGHLIGHTS 

Download PDF of research highlights from this project.

PUBLICATIONS

See individual staff webpages for current list of publications from this project.

Facilities and capabilities

Download PDF of facilities and capabilities for this project.

Post-DocTORAL OPPORTUNITIES 

This project normally has 2-year post-doctoral fellowships with competitive pay available for US citizens (see links to specific opportunities below).  These fellowships are through the competitive, proposal-based National Research Council Research Associateship Program (NRC-RAP).  NIST participates in two of the application cycles (Feb 1 and August 1) each year.  Applicants should plan to work closely with NIST staff to develop their research proposals in order to ensure programmatic fit and suitable resources for the proposed work. 

1. Fatigue and Fracture of Metallic Materials Processed via Additive Manufacturing 
2. Nondestructive Evaluation of Additively Manufactured Alloys

awards

• 2024 ASTM International Award of Excellence for Additive Manufacturing Standardization - Nik Hrabe
• 2024 NIST Material Measurement Laboratory Early Career Accolade - Nicholas Derimow
• 2023 US Department of Commerce Bronze Medal - Nicholas Derimow, Jake Benzing, Newell Moser, Orion Kafka, Nik Hrabe 
• 2023 ASTM International Additive Manufacturing Young Professional Award – Jake Benzing
• 2023 NIST Material Measurement Laboratory Early Career Accolade – Jake Benzing
• 2023 NIST Material Measurement Laboratory Postdoctoral Fellow Accolade – Orion Kafka
• 2023 NIST Postdoctoral and Early Career Association of Researchers (PEAR) Postdoctoral Accolade – Orion Kafka
• 2022 NIST Material Measurement Laboratory Postdoctoral Fellow Accolade – Newell Moser
• 2021 NIST Material Measurement Laboratory Postdoctoral Fellow Accolade – Nicholas Derimow
• 2020 NIST Material Measurement Laboratory Postdoctoral Fellow Accolade – Jake Benzing
• 2020 NIST Material Measurement Laboratory Distinguished Mentor Accolade – Nik Hrabe
• 2020 ASTM International Additive Manufacturing Young Professional Award – Nik Hrabe