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Measuring Overhang Down-Skin Dross Depth and the Inter-Dependency on Melt Pool for Laser Powder Bed Fusion Additive Manufacturing

August 20, 2024

Author(s)

Zhuo Yang, Jaehyuk Kim, Brandon Lane, Yan Lu

The overhang down-skin surface exhibits distinct behaviors compared to the regular up-skin surface in the powder bed fusion process. Evidence suggests that weak support could be the primary cause of these differences. Previous studies by the authors have

Pyramid Learning Based Part-to-Part Consistency Analysis in Laser Powder Bed Fusion

August 20, 2024

Author(s)

Erfan Ziad, Feng Ju, Zhuo Yang, Yan Lu

With the rapid growth of the manufacturing industry, laserbased metal additive manufacturing, such as laser powder bed fusion, has the potential to usher in a revolution. However, its widespread adoption is contingent on the resolution of severa

Co-Ni-Al-W gamma/gamma prime Superalloy with Cr and Ti additions Fabricated via Laser Fusion of Elemental Powders

August 17, 2024

Author(s)

Hye Ji Im, Julio Cesar Pereira Dos Santos, Carelyn Campbell, David Dunand

A Co-based superalloy (Co-0.20Ni-0.11Al-0.07W-0.04Cr-0.03Ti, mole fraction) was synthesized by laser powder-bed fusion of a blend of elemental powders. The as-built alloy shows a γ-FCC matrix where the high-melting Ti and Cr powders are fully dissolved

Defect Recrystallization in Subtransus Hot Isostatic Pressing of Electron Beam Powder Bed Fusion Ti-6Al-4V

August 14, 2024

Author(s)

Alec Saville, Jake Benzing, S. Lee Semiatin, Nicholas Derimow, Nik Hrabe

Post-build hot isostatic pressing (HIP) is a widely used method to close as-built defects (gas or lack-of-fusion porosity) in additively manufactured (AM) metal parts. Pore closure during this process often creates clusters of equiaxed grains, in contrast

Ontology-based Retrieval Augmented Generation (RAG) for GenAI-supported Additive Manufacturing

August 14, 2024

Author(s)

Yeun Park, Paul Witherell, Nowrin Akter Surovi, Hyunbo Cho

Conventional data analytics often fail to capture the intricate context of Additive Manufacturing (AM) processes, leading to pointed solutions and suboptimal analytics outcomes. The performance of Generative AI (GenAI) models, such as Large Language Models

Engineering-Guided Deep Learning of Melt-pool Dynamics for Additive Manufacturing Quality Monitoring

August 6, 2024

Author(s)

Siqi Zhang, Hui Yang, Zhuo Yang, Yan Lu

Additive manufacturing fabricates three-dimensional parts via layer-by-layer deposition and solidification of materials. Due to the complexity of this process, advanced sensing is increasingly employed to facilitate system visibility, leading to a large

Additive Manufacturing of Highly Entangled Polymer Networks

August 1, 2024

Author(s)

Abhishek Dhand, Matthew Davidson, Hannah Zlotnick, Thomas Kolibaba, Jason Killgore, Jason Burdick

Incorporation of polymer chain entanglements within a single network can synergistically improve stiffness and toughness, yet attaining such dense entanglements through vat photopolymerization additive manufacturing (e.g., digital light processing, DLP)

A Reference Activity Model for Additive Manufacturing: Powder Bed Fusion

July 26, 2024

Author(s)

Duncan Gibbons, Paul Witherell

Empowering Small and Medium-Sized Enterprises Through Effective Additive Manufacturing Data Management

July 24, 2024

Author(s)

Yan Lu, Paul Witherell, William Frazier

This report summarizes the results of the workshop entitled "Empowering Small and Medium Size Enterprises Through Effective Additive Manufacturing Data Management." NIST co-hosted the event in partnership with the National Manufacturing Innovative

A Collaborative Study on The Characterization of Additive Manufacturing Build Surfaces and Solidified Melt Pool Topography

July 15, 2024

Author(s)

Jason Fox, Jesse Redford, Christopher Evans

Scan Strategy Based Measurands For Characterization of Surface Topography in Laser Powder Bed Fusion

July 15, 2024

Author(s)

Jason Fox, Jesse Redford, Christopher Evans

Specification and Characterization of Laser Powder Bed Fusion Surface Textures for Heat Transfer in Internal Channels

July 15, 2024

Author(s)

M M Towfiqur Rahman, Chris Evans, Jason Fox, Jimmie Miller, Jaime Berez

Metal additive manufacturing (AM) and particularly, laser powder bed fusion (LPBF), is a candidate process for the manufacture of intricate internal cooling channels used in heat transfer applications. Although unique geometries optimal for heat transfer

Generative Artificial Intelligence (GenAI) Prompt Engineering for Additive Manufacturing (AM)

July 1, 2024

Author(s)

Nowrin Akter Surovi, Paul Witherell

Additive manufacturing (AM) faces several challenges in achieving efficient and defect-free printing. Although traditional machine learning (ML) has proven effective in mitigating these challenges, it requires specialized models for solving specific

CHARACTERIZATION OF ELASTOPLASTIC PROPERTIES OF ADDITIVELY MANUFACTURED SPECIMENS FROM INDENTATION DATA USING STOCHASTIC INVERSE MODELING

June 17, 2024

Author(s)

Ridwan Olabiyi, Jordan Weaver, Ashif Sikandar Iquebal

Rapid characterization of the mechanical properties and material structure of additively manufactured components via nondestructive techniques is becoming the sine-qua-non for their wider adoption. In this research, we primarily focus on estimating the ela

Tailoring Properties of 3D-Printable Polyelectrolyte Photopolymer Complexes with Reactive Diluents

June 14, 2024

Author(s)

Thomas Kolibaba, Callie Higgins, Benjamin Caplins, Elisabeth Mansfield, Caleb Chandler, Jason Killgore

Polyelectrolyte complexes (PECs), ionically bound assemblies of oppositely charged polymers, have wide ranging applications spanning medicine, fire safety, and electronic materials. For years, PECs presented processing challenges owing to their ionic bonds

A technique for in-situ displacement and strain measurement with laboratory-scale X-ray Computed Tomography

May 23, 2024

Author(s)

Orion Kafka, Alexander Landauer, Jake Benzing, Newell Moser, Elisabeth Mansfield, Edward Garboczi

Purpose: Establish a technique for simultaneous interrupted volumetric imaging of internal structure and time-resolved full-field surface strain measurements during in-situ X-ray micro-computed tomography (XCT) experiments. This enables in-situ testing of

Correction: A Technique for In-Situ Displacement and Strain Measurement with Laboratory-Scale X-Ray Computed Tomography

May 23, 2024

Author(s)

Orion Kafka, Alexander Landauer, Jake Benzing, Newell Moser, Elisabeth Mansfield, Edward Garboczi

The inverse heat placement problem in metal additive manufacturing: Why a rational approach is needed for powder bed fusion

May 15, 2024

Author(s)

John Billingham, Ho Yeung, Dragos Axinte, Zhirong Liao, Jason Fox

Powder bed fusion (PBF) uses an energy beam to scan a powder bed surface, heat it locally and consolidate the material to form a part. The choice of energy beam paths is typically based on user experience. Simple beam path strategies (e.g., raster or

Cross-Sectional Melt Pool Geometry of Laser Scanned Tracks and Pads on Nickel Alloy 718 for the 2022 Additive Manufacturing Benchmark Challenges

May 7, 2024

Author(s)

Jordan Weaver, David Deisenroth, Sergey Mekhontsev, Brandon Lane, Lyle E. Levine, Ho Yeung

AM Bench is a NIST-led organization that provides a continuing series of additive manufacturing (AM) benchmark measurements, challenge problems, and conferences with the primary goal of enabling modelers to test their simulations against rigorous, highly

Benchmark Study of Melt Pool and Keyhole Dynamics, Laser Absorption, and Porosity in Additive Manufacturing of Ti-6Al-4V

April 29, 2024

Author(s)

Arash Samaei, Joseph Leonor, zhengtao gan, Zhongsheng Sang, Xiaoyu Xie, Brian Simonds, Wing Kam Liu, Gregory Wagner

Metal 3D printing involves a multitude of operational and material parameters that exhibit intricate interdependencies, which pose challenges to real-time process optimization, monitoring, and controlling. The dynamic behavior of the laser-induced melt

Quality by Design Considerations for Drop-on-Demand Point-of-Care Pharmaceutical Manufacturing of Precision Medicine

April 25, 2024

Author(s)

Thomas P. Forbes, J Greg Gillen, William Feeney, Johnny Ho

Distributed and point-of-care (POC) manufacturing facilities enable an agile pharmaceutical production paradigm that can respond to localized needs, providing personalized and precision medicine. These capabilities are critical for narrow therapeutic index

Current State and Benchmarking Generative Artificial intelligence for Additive Manufacturing

April 22, 2024

Author(s)

Nowrin Akter Surovi, Paul Witherell, Kumara Sundar, Vinay Saji Mathew

Additive Manufacturing (AM) is becoming increasingly popular in academia and industry due to its cost-effectiveness and time-saving benefits. However, AM faces several challenges that must be addressed to enhance its efficiency. While Machine Learning (ML)

Solidification behavior and texture of 316L austenitic stainless steel by laser wire directed energy deposition

April 18, 2024

Author(s)

Olivia DeNonno, Alec Saville, Jake Benzing, Jonah Klemm-Toole, Zhenzhen Yu

The solidification behavior and crystallographic texture of 316L austenitic stainless steel builds fabricated via laser-wire directed energy deposition additive manufacturing (AM) were investigated. Shielding gas set-up and build type (single-track vs

Computational analysis and experiments of spatter transport in a laser powder bed fusion machine

April 16, 2024

Author(s)

Nicholas O'Brien, Syed Uddin, Jordan Weaver, Jake Jones, Satbir Singh, Jack Beuth

This work focuses on how spatter particles are transported within a laser powder bed fusion (L-PBF) machine. The machine's gas flow rate and salient flow features are studied with a computational fluid dynamics (CFD) model and are validated with

Evaluating Models That Predict Epoxy Conversion Using Rheological Properties

April 15, 2024

Author(s)

Stian Romberg, Paul Roberts, Chad R. Snyder, Anthony Kotula

Simultaneous rheology and conversion measurements of neat and composite epoxy resins reveal that conventional models neither accurately nor fully describe the relationship between rheology and conversion. We find that models predicting thermoset conversion

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