Deciphering the Fracture Initiation Mechanism in Additive-Manufactured 17-4 Steel
AbstractAdditive manufacturing (AM) provides exceptional geometrical freedom to the architects and designers and enables the construction of architecturally exposed steel structures. However, the AM structural elements inherently possess microscale defects that can affect their ductility. This study...
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| Published in: | Journal of materials in civil engineering Vol. 36; no. 6 |
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| Main Authors: | , , |
| Format: | Journal Article |
| Language: | English |
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American Society of Civil Engineers
01-06-2024
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| Abstract | AbstractAdditive manufacturing (AM) provides exceptional geometrical freedom to the architects and designers and enables the construction of architecturally exposed steel structures. However, the AM structural elements inherently possess microscale defects that can affect their ductility. This study aims to identify the fracture-initiating mechanism in AM 17-4 stainless steel that is popularly used owing to its excellent engineering properties. To this end, axisymmetric cylindrical notched and unnotched tension specimens are manufactured employing direct metal laser sintering from 17-4 stainless steel powder with established processing and build parameters. The test specimens were manufactured using a 90° build orientation with the build plate and a layer thickness of 40 μm. Postprocessing heat treatment was avoided as the study focused on understanding the failure mechanism in as-built AM test specimens. Detailed metallurgical analysis is performed employing scanning electron microscopy (SEM) and electron backscatter diffraction. Subsequently, micro–computed tomography (CT) studies are conducted on the tension specimens before and after mechanical testing. Although the SEM analyses of fracture surfaces are inconclusive, the micro-CT analysis revealed evidence of nucleation of new microvoids, growth of existing voids, and void coalescence in the vicinity of the fracture surface, which is unequivocal evidence for ductile fracture. Furthermore, the larger AM defects were found to play an important role in lowering the ductility in addition to stress concentration, and the fracture was initiated when the AM defects coalesced over a length of around 600 μm. The conclusions of this study emphasize the importance of controlling the maximum size of defects in AM structural elements to improve their performance. |
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| AbstractList | Additive manufacturing (AM) provides exceptional geometrical freedom to the architects and designers and enables the construction of architecturally exposed steel structures. However, the AM structural elements inherently possess microscale defects that can affect their ductility. This study aims to identify the fracture-initiating mechanism in AM 17-4 stainless steel that is popularly used owing to its excellent engineering properties. To this end, axisymmetric cylindrical notched and unnotched tension specimens are manufactured employing direct metal laser sintering from 17-4 stainless steel powder with established processing and build parameters. The test specimens were manufactured using a 90° build orientation with the build plate and a layer thickness of 40 μm. Postprocessing heat treatment was avoided as the study focused on understanding the failure mechanism in as-built AM test specimens. Detailed metallurgical analysis is performed employing scanning electron microscopy (SEM) and electron backscatter diffraction. Subsequently, micro–computed tomography (CT) studies are conducted on the tension specimens before and after mechanical testing. Although the SEM analyses of fracture surfaces are inconclusive, the micro-CT analysis revealed evidence of nucleation of new microvoids, growth of existing voids, and void coalescence in the vicinity of the fracture surface, which is unequivocal evidence for ductile fracture. Furthermore, the larger AM defects were found to play an important role in lowering the ductility in addition to stress concentration, and the fracture was initiated when the AM defects coalesced over a length of around 600 μm. The conclusions of this study emphasize the importance of controlling the maximum size of defects in AM structural elements to improve their performance. AbstractAdditive manufacturing (AM) provides exceptional geometrical freedom to the architects and designers and enables the construction of architecturally exposed steel structures. However, the AM structural elements inherently possess microscale defects that can affect their ductility. This study aims to identify the fracture-initiating mechanism in AM 17-4 stainless steel that is popularly used owing to its excellent engineering properties. To this end, axisymmetric cylindrical notched and unnotched tension specimens are manufactured employing direct metal laser sintering from 17-4 stainless steel powder with established processing and build parameters. The test specimens were manufactured using a 90° build orientation with the build plate and a layer thickness of 40 μm. Postprocessing heat treatment was avoided as the study focused on understanding the failure mechanism in as-built AM test specimens. Detailed metallurgical analysis is performed employing scanning electron microscopy (SEM) and electron backscatter diffraction. Subsequently, micro–computed tomography (CT) studies are conducted on the tension specimens before and after mechanical testing. Although the SEM analyses of fracture surfaces are inconclusive, the micro-CT analysis revealed evidence of nucleation of new microvoids, growth of existing voids, and void coalescence in the vicinity of the fracture surface, which is unequivocal evidence for ductile fracture. Furthermore, the larger AM defects were found to play an important role in lowering the ductility in addition to stress concentration, and the fracture was initiated when the AM defects coalesced over a length of around 600 μm. The conclusions of this study emphasize the importance of controlling the maximum size of defects in AM structural elements to improve their performance. |
| Author | Kiran, Ravi Dey, Surajit Anto, Anik Das |
| Author_xml | – sequence: 1 givenname: Anik Das surname: Anto fullname: Anto, Anik Das email: aanto@vols.utk.edu organization: Univ. of Tennessee Knoxville Graduate Research Assistant, Dept. of Mechanical, Aerospace and Biomedical Engineering, , Knoxville, TN 37996. Email – sequence: 2 givenname: Surajit surname: Dey fullname: Dey, Surajit email: sdey34@asu.edu organization: Arizona State Univ. Graduate Research Assistant, School of Sustainable Engineering and Built Environment, , Tempe, AZ 85281. Email – sequence: 3 givenname: Ravi surname: Kiran fullname: Kiran, Ravi email: ravi.kiran@asu.edu organization: Arizona State Univ. Associate Professor, School of Sustainable Engineering and Built Environment, , Tempe, AZ 85281 (corresponding author). ORCID: . Email |
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| Snippet | AbstractAdditive manufacturing (AM) provides exceptional geometrical freedom to the architects and designers and enables the construction of architecturally... Additive manufacturing (AM) provides exceptional geometrical freedom to the architects and designers and enables the construction of architecturally exposed... |
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| SubjectTerms | Computed tomography Crack initiation Defects Ductile fracture Ductility Electron back scatter Failure mechanisms Fracture mechanics Fracture surfaces Heat treatment Laser sintering Mechanical tests Metallurgical analysis Nucleation Scanning electron microscopy Sintering (powder metallurgy) Stainless steel Stainless steels Stress concentration Structural members Technical Papers Thickness |
| Title | Deciphering the Fracture Initiation Mechanism in Additive-Manufactured 17-4 Steel |
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