The Laser-based Powder Bed Fusion of Metals (PBF-LB/M) process has shown potential in the manufacturing of critical flight components, yet also has faced difficulties in achieving reproducibility. One potential reason for this is that tensile testing, which is one of the methods traditionally used to ascertain quality in the additive manufacturing (AM) industry, is insufficient for capturing underlying flaws in an additively manufactured component. To quantify the ability of tensile testing to detect underlying flaws in a component, a generalized full factorial experiment was performed where the tensile properties of UNS N07718 were measured across several types of build conditions. Combinations of differently sized bars and surface conditions were investigated. Defects were induced by amplifying the polygon delay parameter, hence prolonging the dwell time of the laser in the contours. The authors found that those tensile bars that experienced increased polygon delay had ∼10x more pores than those built with nominal parameter values while still maintaining an average porosity of <0.25 % (i.e., a total part porosity that is acceptable by NASA-STD-6030). Regardless of the specimen geometry and surface condition, differences between parts which had undergone polygon delay and those that had not were either statistically insignificant or were too small to be relevant, indicating that tensile testing may not be an effective metric for identifying the quality of a PBF-LB/M process.
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