Test Artifacts Research Articles

Generalized SmartScan: An Intelligent LPBF Scan Sequence Optimization Approach for Reduced Residual Stress and Distortion in 3D Part Geometries

Abstract Laser powder bed fusion (LPBF) is an additive manufacturing technique that is gaining popularity for producing metallic parts in various industries. However, parts produced by LPBF are prone to residual stress, deformation, cracks and other quality defects due to uneven temperature distribution during the LPBF process. To address this issue, in prior work, the authors have proposed SmartScan, a method for determining laser scan sequence in LPBF using an intelligent (i.e., model-based and optimization-driven) approach, rather than using heuristics, and applied it to simple 2D geometries. This paper presents a generalized SmartScan methodology that is applicable to arbitrary 3D geometries. This is achieved by: (1) expanding the thermal model and optimization approach used in SmartScan to multiple layers; (2) enabling SmartScan to process shapes with arbitrary contours and infill patterns within each layer; (3) providing the optimization in SmartScan with a balance of exploration and exploitation to make it less myopic; and (4) improving SmartScan’s computational efficiency via model order reduction using singular value decomposition. Sample 3D test artifacts are simulated and printed using SmartScan in comparison with common heuristic scan sequences. Reductions of up to 92% in temperature inhomogeneity, 86% in residual stress, 24% in maximum deformation and 50% in geometric inaccuracy were observed using SmartScan. An approach for using SmartScan for printing complex 3D parts in practice, by integrating it as a plug-in to a commercial slicing software, was also demonstrated experimentally, along with its benefits in significantly improving printed part quality.

Effect of sintering temperature on feature resolution and flexural strength of ceramics fabricated through vat photopolymerization additive manufacturing

PurposeAlthough ceramic additive manufacturing (AM) could be used to fabricate complex, high-resolution parts for diverse, functional applications, one ongoing challenge is optimizing the post-process, particularly sintering, conditions to consistently produce geometrically accurate and mechanically robust parts. This study aims to investigate how sintering temperature affects feature resolution and flexural properties of silica-based parts formed by vat photopolymerization (VPP) AM.Design/methodology/approachTest artifacts were designed to evaluate features of different sizes, shapes and orientations, and three-point bend specimens printed in multiple orientations were used to evaluate mechanical properties. Sintering temperatures were varied between 1000°C and 1300°C.FindingsDeviations from designed dimensions often increased with higher sintering temperatures and/or larger features. Higher sintering temperatures yielded parts with higher strength and lower strain at break. Many features exhibited defects, often dependent on geometry and sintering temperature, highlighting the need for further analysis of debinding and sintering parameters.Originality/valueTo the best of the authors’ knowledge, this is the first time test artifacts have been designed for ceramic VPP. This work also offers insights into the effect of sintering temperature and print orientation on flexural properties. These results provide design guidelines for a particular material, while the methodology outlined for assessing feature resolution and flexural strength is broadly applicable to other ceramics, enabling more predictable part performance when considering the future design and manufacture of complex ceramic parts.

Measurement systems analysis for beam compensation, scaling factors and geometric dimensioning for a metallic additively manufactured test artifact

Measurement systems analysis for beam compensation, scaling factors and geometric dimensioning for a metallic additively manufactured test artifact

Review of surface metrology artifacts for additive manufacturing

Test artifacts, resembling real machine parts, allow quantitative evaluation of system performance and insight into individual errors, aiding in improvement and standardization in additive manufacturing. The article provides a comprehensive overview of existing test artifacts, categorized based on geometric features and material used. Various measurement techniques such as stylus profilometry and computed tomography are employed to assess these artifacts. It was shown that Selective Laser Melting (SLM) technology and titanium alloys are prevalent in artifact creation. Specific artifact categories include slits, angular aspects, length parameters, variable surfaces, and others, each accompanied by examples from research literature, highlighting diverse artifact designs and their intended applications. The paper critically discusses the main problems with existing geometries. It paper underscores the importance of user-friendly and unambiguous artifacts for dimensional control, particularly in surface metrology. It anticipates the continued growth of metrological verification in future manufacturing environments, emphasizing the need for precise and reliable measurement results to support decision-making in production conditions

Geometric Benchmarking of Metal Material Extrusion Technology: A Preliminary Study

Metal additive manufacturing technologies such as powder bed fusion (PBF) and direct energy deposition (DED) are experiencing fast development, due to the growing awareness of industries. However, high energy consumption, slow production processes, and high costs of both machines and feedstocks hamper their competitiveness, compared to conventional manufacturing techniques. Metal material extrusion (metal-MEX) can represent a cost- and energy-effective alternative for metal additive manufacturing. This article aims to assess the potential of such technology by addressing uncertainties related to product design and process stability through a preliminary geometric benchmarking study. The geometric tolerances and minimum achievable sizes of some simple geometries produced in 316L stainless steel were evaluated using geometric benchmark test artifacts (GBTAs). Process maps were also proposed to forecast the feasibility of achieving acceptable values of the investigated tolerances, based on the nominal dimensions of the features.

Location-Specific Microstructure Characterization Within AM Bench 2022 Nickel Alloy 718 3D Builds

The Additive Manufacturing Benchmark Test Series (AM Bench) is a broad effort to produce rigorous measurement datasets for validating AM computer simulations across the range of processing, structure, and properties, for many additive manufacturing (AM) build methods and material classes. Here, the microstructures of nickel alloy 718 AM Bench 2022 test artifacts produced using laser-based powder bed fusion (PBF-LB), in both as-built and fully heat-treated conditions, are examined. Cross sections are primarily characterized using large area scanning electron microscopy (SEM) electron backscatter diffraction (EBSD) and example analyses of the crystallographic textures are described. These data are part of a large set of in situ and ex situ measurements from both three-dimensional builds and laser tracks on bare plates. All the measurement data are available online with download links at www.nist.gov/ambench.

Dimensional Characterization and Hybrid Manufacturing of Copper Parts Obtained by Atomic Diffusion Additive Manufacturing, and CNC Machining.

The combination of Atomic Diffusion Additive Manufacturing (ADAM) and traditional CNC machining allows manufacturers to leverage the advantages of both technologies in the production of functional metal parts. This study presents the methodological development of hybrid manufacturing for solid copper parts, initially produced using ADAM technology and subsequently machined using a 5-axis CNC system. The ADAM technology was dimensionally characterized by adapting and manufacturing the seven types of test artifacts standardized by ISO/ASTM 52902:2019. The results showed that slender geometries suffered warpage and detachment during sintering despite complying with the design guidelines. ADAM technology undersizes cylinders and oversizes circular holes and linear lengths. In terms of roughness, the lowest results were obtained for horizontal flat surfaces, while 15° inclined surfaces exhibited the highest roughness due to the stair-stepping effect. The dimensional deviation results for each type of geometry were used to determine the specific and global oversize factors necessary to compensate for major dimensional defects. This also involved generating appropriate over-thicknesses for subsequent CNC machining. The experimental validation of this process, conducted on a validation part, demonstrated final deviations lower than 0.5% with respect to the desired final part, affirming the feasibility of achieving copper parts with a high degree of dimensional accuracy through the hybridization of ADAM and CNC machining technologies.

Axiomatic Design of a Test Artifact for PBF-LM Machine Capability Monitoring

Powder Bed Fusion Laser Melting (PBF-LM) additive manufacturing technology is expected to have a remarkable impact on the industrial setting, making possible the realization of a metallic component with very complex designs to enhance product performance. However, the industrial use of the PBF-LM system needs a capability monitoring system to ensure product quality. Among the various studies developed, the investigation of methodology for the actual machine capability determination has been faced and still represents an open point. There are multiple authors and institutes proposing different investigation methods, ranging from the realization of samples (ex situ analysis) to installing monitoring devices on the machine (in situ analysis). Compared to other approaches, sample realization allows for assessing how the machine works through specimen analysis, but it is sensitive to the sample design. In this article, we first present an analysis of a well-known test artifact from an Axiomatic Design perspective. Second, based on the customer needs analysis and adjustments with respect to the use of hypothetical additive production lines, a new test artifact with an uncoupled design matrix is introduced. The proposed design has been experimentally tested and characterized using artifact made of Inconel 718 superalloy to evaluate its performance and representativeness in machine capability assessment. The results show an accurate identification of beam offset and scaling factor considering all the building platform positions. In addition, the artifact is characterized by a reduced building time (more than 90% with respect to the reference NIST artifact) and a halved inspection time (from 16 h to 8 h).

Insights Into Vestibulo-Ocular Reflex Artifacts: A Narrative Review of the Video Head Impulse Test (vHIT).

Video head impulse test (vHIT) artifacts are defined as spurious elements or disturbances in the recorded data that deviate from the true vestibulo-ocular reflexresponse. These artifacts can arise from various sources, encompassing technological limitations, patient-specific factors, or environmental influences, introducing inaccuracies in vHIT outcomes. The absence of standardized criteria for artifact identification leads to methodological heterogeneity. This narrative review aims to comprehensively examine the challenges posed by artifacts in the vHIT. By surveying existing literature, the review seeks to elucidate the multifaceted nature of artifacts arising from technological, patient-related, evaluator-related, and environmental factors.

Improving the rigor and reproducibility of catalyst testing and evaluation in the laboratory

Experimental testing and evaluation of catalysts in reactors is a central feature of fundamental catalysis science and reaction engineering. Measurements must be reproducible and interpretable to provide evidence for mechanistic studies or structure–function relationships, or to yield robust and intrinsically meaningful parameters to enable reactor scale-up and process development. Consequently, catalysis practitioners should seek to plan and perform catalyst testing in a manner that distinguishes between the intrinsic chemical kinetics governed by the catalyst and hydrodynamic, transport, and deactivation processes introduced by the form of the catalyst, the reactor vessel, and the nature of the contacting fluid. We highlight the importance of clear testing procedures for both the individual practitioner and the catalysis community and then discuss the sources and methods to address key sources of artifacts in catalyst testing. We organize sections in the form of questions practitioners should ask themselves when planning a catalyst testing campaign. This article references the original literature but also recasts the catalyst testing procedure in the form of a workflow diagram and illustrated depictions of the control experiments implemented within our laboratories to minimize the occurrence of artifacts. The content reflects our collective knowledge in the design, set up, and use of laboratory scale reactors for catalyst testing.

A holistic approach for evaluation of Gaussian versus ring beam processing on structure and properties in laser powder bed fusion

In this study, a holistic evaluation strategy employing a complex test artifact, coupled with single line scan tracks, was employed to examine the influence of different laser beam energy profiles on various features of laser-based powder bed fusion of metals (PBF-LB/M). Using IN718, results revealed a significant influence of the laser beam on bead geometry. Specifically, the conventional Gaussian beam produced deeper, concave-shaped melt pools, while the ring beam resulted in wider and shallower beads. In terms of productivity, the artifacts (two each) fabricated using the Gaussian beam required 6 h and 6 min of build time, while those built using ring beam required only 3 h and 49 min (37% build time reduction) but a defocused Gaussian beam (not included in this study) can match the productivity of the ring beam. However, the holistic approach using the complex test artifact highlighted drawbacks associated with the ring beam, including increased lack of fusion porosity, compromised resolution for features below 0.5 mm, and less than 10% elongation to break in both as built and heat-treated conditions. While acknowledging the potential for improvement through further process optimization, the study concludes that the shallower melt pools produced by the ring beam may cause limitations as layer thicknesses increase. Microstructural analysis revealed distinct grain characteristics, with the Gaussian beam producing more equiaxed grains and the ring beam favouring columnar grains positioned along the build direction. The work primarily highlights the need for and benefits from a holistic analysis in PBF-LB/M technology, ensuring data driven outcomes.

Euramet RMO supplementary comparison low pressure air flow between 25m3/h and 400 m3/h

Main textThe purpose of this Supplementary Comparison (SC) for "Low Pressure Air Flow" measurement is to support the Calibration and Measurement Capabilities (CMC) of the participating National Metrology Institutes and Designated Institutes according to CIPM MRA-G-13. The outcome of this comparison should lead to 'a clear and unequivocal' comparison of measurement results between participants.The comparison was performed over the span of one year which started in March 2021 with the determination of the volume flow rate error of the test artifact by VSL. The test artifact was shipped to each participant where they also determined the volume flow rate error in turn. At the completion by all participants, the artifact was shipped back to VSL for a final calibration to show the stability of the artifact.To reach the main text of this paper, click on Final Report. Note that this text is that which appears in Appendix B of the BIPM key comparison database https://www.bipm.org/kcdb/.The final report has been peer-reviewed and approved for publication by the CCM, according to the provisions of the CIPM Mutual Recognition Arrangement (CIPM MRA).

Parameter and Deposition Strategy Analysis for WAAM Processing of AISI 410 Stainless Steel

Wire + Arc Additive Manufacturing (WAAM®) is an additive manufacturing (AM) process capable of producing near net shape parts while reducing costs and thus gathering increased attention from researchers and manufacturers. Although a significant amount of work has already been published relating to the WAAM processing of stainless steels, it was mainly focused on austenitic stainless steels, with martensitic grades still lacking investigation. AISI 410 is a martensitic stainless steel that, due to its high hardness, demonstrates high wear resistance, being used in parts requiring high resistance to abrasion. Processing this material by WAAM allows for the creation of near net shape parts, leading to a reduction in machining, while at the same time allowing the creation of complex geometries which would be difficult, or outright impossible to obtain otherwise. In this work the effects of different processing parameters on WAAM processed AISI 410 steel, using Cold Metal Transfer (CMT) welding equipment, were investigated, as well as different deposition strategies for the fabrication of a test artifact using an AM software. It was demonstrated that it is possible to process AISI 410 steel by WAAM using an AM software to define deposition strategies and parameters based on the part design and previous experimental trials. The goal to deposit a complex part with high hardness and tensile strength, especially attractive properties to parts requiring high resistance to wear was achieved.

Quality Analysis of Micro-Holes Made by Polymer Jetting Additive Manufacturing.

Material jetting technology is gaining popularity, especially in polymer science, because of their high accuracy for additive manufacturing (AM) products. This paper aims to investigate the quality of micro-holes that are oriented in three basic directions, and manufactured by the material jetting AM process. This paper proposes a novel methodology to evaluate the accuracy of micro-holes features by using a transparent artifact. A test artifact with horizontal and vertical micro-holes in it, with industrial applications, was designed. Micro-holes were placed on planar and curve surfaces. Samples were manufactured by PolyJet technology from a translucent photopolymer resin which allows a facile investigation (by microscopy) of the inner structure of the micro-holes. The features of ten micro-holes printed in matte and glossy finish type, with diameters in coarse and medium options, according to ISO/ASTM 52902, were analyzed. Quality analysis of the micro-holes features was performed by microscopy investigations. The effects of main factors on the deviation of the micro-hole diameter were investigated by using the statistical design of experiments, and four control factors were considered. The best results were obtained for sample printed in matte finishing with the micro-holes oriented along the x-axis and z-axis. The smallest diameter of the micro-holes obtained by PolyJet technology on an EDEN 350 machine was 0.5 mm, but in industrial applications for a facile post-processing, a higher diameter is recommended to be used. A confirmatory experiment on a wing sample, with a number of micro-holes of the same diameter and a large length to diameter ratio of the micro-holes, was performed, and the repeatability of the results was confirmed.

Code review guidelines for GUI-based testing artifacts

Code review guidelines for GUI-based testing artifacts

Toward a digital materials mechanical testing lab

To accelerate the growth of Industry 4.0 technologies, the digitalization of mechanical testing laboratories as one of the main data-driven units of materials processing industries is introduced in this paper. The digital lab infrastructure consists of highly detailed and standard-compliant materials testing knowledge graphs for a wide range of mechanical testing processes, as well as some tools that enable the efficient ontology development and conversion of heterogeneous materials’ mechanical testing data to the machine-readable data of uniform and standardized structures. As a basis for designing such a digital lab, the mechanical testing ontology (MTO) was developed based on the ISO 23718 and ISO/IEC 21838-2 standards for the semantic representation of the mechanical testing experiments, quantities, artifacts, and report data. The trial digitalization of materials mechanical testing lab was successfully performed by utilizing the developed tools and knowledge graph of processes for converting the various experimental test data of heterogeneous structures, languages, and formats to standardized Resource Description Framework (RDF) data formats. The concepts of data storage and data sharing in data spaces were also introduced and SPARQL queries were utilized to evaluate how the introduced approach can result in the data retrieval and response to the competency questions. The proposed digital materials mechanical testing lab approach allows the industries to access lots of trustworthy and traceable mechanical testing data of other academic and industrial organizations, and subsequently organize various data-driven research for their faster and cheaper product development leading to a higher performance of products in engineering and ecological aspects.

The influence of lubricant temperature on the wear of total knee replacements

AbstractExperimental in vitro simulation can be used to predict the wear performance of total knee replacements. The in vitro simulation should aim to replicate the in vivo loading, motion and environment experienced by the joint, predicting wear and potential failure whilst minimising test artefacts. Experimental wear simulation can be sensitive to environmental conditions; the environment temperature is one variable which should be controlled and was the focus of this investigation. In this study, the wear of an all‐polymer (PEEK‐OPTIMA™ polymer‐on‐UHMWPE) total knee replacement and a conventional cobalt chrome‐on‐UHMWPE implant of similar initial surface topography and geometry were investigated under elevated temperature conditions. The wear was compared to a previous study of the same implants under simulator running temperature (i.e. without heating the test environment). Under elevated temperature conditions, the wear rate of the UHMWPE tibial inserts was low against both femoral component materials (mean <2 mm3/million cycles) and significantly lower (p < 0.05) than for investigations at simulator running temperature. Protein precipitation from the lubricant onto the component articulating surfaces is a possible explanation for the lower wear. This study highlights the need to understand the influence of different variables including environmental temperature to minimise the test artefacts during wear simulation which may affect the wear rates.

TOWARDS REALISTIC NUMERICAL MODELLING OF THIN STRUT-BASED 3D-PRINTED STRUCTURES

AbstractThe as-built geometry and material properties of parts manufactured using Additive Manufacturing (AM) can differ significantly from the as-designed model and base material properties. These differences can be more pronounced in thin strut-like features (e.g., in a lattice structure), making it essential to incorporate them when designing for AM and predicting their structural behaviour. Therefore, the aim of this study is to develop a numerical model with realistic characteristics based on a thin strut-based test artefact and to use it accurately for estimating its compressive strength. Experiments on test samples produced by selective laser sintering in PA 1101, are used to calculate geometrical deviations, Young's modulus, and yield strength, which are used to calibrate the numerical model. The experimental and numerical results show that the numerical model incorporating geometrical and material deviations can accurately predict the peak load and the force-displacement behaviour. The main contributions of this paper include the design of the test artefact, the average geometrical deviation of the struts, the measured material data, and the developed numerical model.

The role of hand preference in cognition and neuropsychiatric symptoms in neurodegenerative diseases.

Handedness has been shown to be associated with genetic variation involving brain development and neuropsychiatric diseases. Whether handedness plays a role in clinical phenotypes of common neurodegenerative diseases has not been extensively studied. This study used the National Alzheimer's Coordinating Center database to examine whether self-reported handedness was associated with neuropsychological performance and neuropsychiatric symptoms in cognitively unimpaired individuals (n = 17 670), individuals with Alzheimer's disease (n = 10 709), behavioural variant frontotemporal dementia (n = 1132) or dementia with Lewy bodies (n = 637). Of the sample, 8% were left-handed, and 2% were ambidextrous. There were small differences in the handedness distributions across the cognitively unimpaired, Alzheimer's disease, behavioural variant frontotemporal dementia and dementia with Lewy bodies groups (7.2-9.5% left-handed and 0.9-2.2% ambidextrous). After adjusting for age, gender and education, we found faster performance in Trail Making Test A in cognitively unimpaired non-right-handers (ambidextrous and left-handed) compared with right-handers. Excluding ambidextrous individuals, the left-handed cognitively unimpaired individuals had faster Trail Making Test A performance and better Number Span Forward performance than right-handers. Overall, handedness had no effects on most neuropsychological tests and none on neuropsychiatric symptoms. Handedness effect on Trail Making Test A in the cognitively unimpaired is likely to stem from test artefacts rather than a robust difference in cognitive performance. In conclusion, handedness does not appear to affect neuropsychological performance or neuropsychiatric symptoms in common neurodegenerative diseases.

First of its kind: a test artifact for direct laser writing

With femtosecond-laser direct writing (fs-LDW) maturing in all aspects as a manufacturing technology, a toolset for quality assurance must be developed. In this work we introduce a first of its kind test artifact. Test artifacts are standardized 3D models with specific geometric features to evaluate the performance of writing parameters. Test artifacts are already common in other 3D additive manufacturing technologies e.g. selective laser melting. The test artifact introduced in this work was developed in particular to accommodate (1) the high geometrical resolution of fs-LDW structures and (2) the limited possibilities to examine the resulting structure. Geometric accuracy, surface adhesion as well as confocal Raman spectroscopy results were considered when evaluating the design of the test artifact. We will explain the individual features and design considerations of our fs-LDW test artifact. The difference between two slicers, Cura and 3DPoli, and the implications on measured feature sizes and the general shape is quantified. The measured geometries are used to derive a general design guide for a specific combination of photoresists, laser power and scanning speed and to analyze the geometric accuracy of a structure produced using these guidelines. The shown test artifact is publicly available as STL file on GitHub (https://github.com/BAMresearch/2PP-TestArtifact) and in the supplement.