Abstract
Advanced manufacturing encompasses the wide range of processes that consist of “3D printing” of metallic materials. One such method is Electron Beam Melting (EBM), a modern build technology that offers significant potential for lean manufacture and a capability to produce fully dense near-net shaped components. However, the manufacture of intricate geometries will result in variable thermal cycles and thus a transient microstructure throughout, leading to a highly textured structure. As such, successful implementation of these technologies requires a comprehensive assessment of the relationships of the key process variables, geometries, resultant microstructures and mechanical properties. The nature of this process suggests that it is often difficult to produce representative test specimens necessary to achieve a full mechanical property characterisation. Therefore, the use of small scale test techniques may be exploited, specifically the small punch (SP) test. The SP test offers a capability for sampling miniaturised test specimens from various discrete locations in a thin-walled component, allowing a full characterisation across a complex geometry. This paper provides support in working towards development and validation strategies in order for advanced manufactured components to be safely implemented into future gas turbine applications. This has been achieved by applying the SP test to a series of Ti-6Al-4V variants that have been manufactured through a variety of processing routes including EBM and investigating the structural integrity of each material and how this controls the mechanical response.
Highlights
Additive layer manufacturing (ALM) is an emerging technology that is rapidly becoming an integral method of component manufacture
For each small punch tensile test deformsdescribed under the applied load, the material experiences an extended phase of plastic bending and throughout this research, the displacement at the onset of failure is defined as the punch membrane stretching
Comparison between pre-scan and post-scan CT data indicates that the feature has reduced slightly in size and the pore opening does not appear to contribute to any crack initiation, likely due to its location meaning it observes the initial compressive load applied in the small punch test rather than the plastic deformation and membrane stretching
Summary
Additive layer manufacturing (ALM) is an emerging technology that is rapidly becoming an integral method of component manufacture. The SP test initially received considerable attention in alternative the 1980soption, for evaluating ductility loss in specimens can be fabricated to characterise the properties of components with thin-wall sections and neutron irradiated materials in nuclear reactors [12,13] and for remnant life assessment of steels in limited dimensions. One such miniaturised test approach is the small punch (SP) test. Experimental Procedures on the mechanical response of the Ti-6Al-4V variants
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