Effect of architecture and process on the ultrasonic mapping of hybrid additively manufactured materials

Abstract

Hybrid additive manufacturing enables the creation of materials with functional microstructure and mechanical property patterns. While samples with functional patterns provide unique advantages in the overall performance of the material, they present a challenge for nondestructive evaluation. In particular, the nondestructive mapping of the properties imparted by hybrid AM processes is critical. In this work, hybrid 316 stainless steel samples are created using laser powder bed fusion (LPBF) with varying hybrid architectures and with a variety of hybrid processes. The ultrasonic responses of these samples, in terms of wave speed, attenuation, and backscatter amplitude, are evaluated for each architecture and process combination. These responses are compared with those from conventionally manufactured samples and traditional AM samples. This evaluation provides information on the sensitivity of ultrasonic responses to hybrid architecture and process, highlighting the potential of ultrasonic nondestructive methods for the characterization of hybrid AM components. [This material is based upon work supported by the National Science Foundation Graduate Research Fellowship Program under Grant No. 1610400. Any opinions, findings, and conclusions or recommendations expressed in this material are those of the author(s) and do not necessarily reflect the views of the National Science Foundation.]