Principal investigator: Albert To
University: University of Pittsburgh
Industry partner: Cumberland Additive
In laser powder bed fusion (L-PBF) additive manufacturing (AM), ensuring consistent build quality remains challenging due to time-consuming and costly post-build testing. To address this issue, this project aims to develop an innovative in-situ fracture test artifact that would crack under the influence of residual stress and jam the recoater blade when certain process anomalies occur during the build process. This fracture mechanism allows the test artifact to be used as a witness coupon to detect process anomaly early and economically. The following project objectives are proposed: 1) Optimizing the test artifact design; 2) Determining the build-to-build and location-dependent variability of the critical fracture height of the test artifact; 3) Understanding the effects of process anomalies on fracture behavior of test artifacts. The outcome of this project will significantly impact the metal AM industry that currently has a market size of $5 billion.