SIM-AM 2023

Metal 3D Builds and In-situ Measurements for the 2022 Additive Manufacturing Benchmark Challenges

  • Lane, Brandon (NIST)
  • Yeung, Ho (NIST)
  • Deisenroth, David (NIST)
  • Mekhontsev, Sergey (NIST)
  • Levine, Lyle (NIST)
  • Phan, Thien (LLNL)

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The Additive Manufacturing Benchmark Test Series (AM-Bench) provides continuing series of highly controlled benchmark tests for additive manufacturing simulation community to assess and improve the prediction capabilities of their models. The 2022 AM-Bench tests included a set metal laser powder bed fusion (LPBF) 3D builds specifically designed to provide various thermal, mechanical, and microstructural reference data. This talk will first describe the design of the 3D builds, including various test artifact features and geometries and their related purposes, and detail the laser scan strategies and scan strategy data. These artifacts were fabricated on the NIST Additive Manufacturing Metrology Testbed (AMMT), and preliminary AMMT system calibrations and characterizations were performed and will be described. Completely new in-situ measurement systems were employed, including a high speed, high magnification thermographic camera providing in-depth detail on the melt pool dynamics. The talk will then focus on these in-situ thermal measurements, with focus on how the thermographic data was collected, processed, and visualized, so that it may be more readily accessed, interpreted, and used by AM modelers. This includes thermal metrics such as time above melt (TAM) and solid cooling rate (SCR) used in the 2022 AM-Bench modelling challenges. Finally, some general observations are provided regarding the modelling challenge results and the relation to thermographic measurement results.