This research will help manufacturers to better understand the 3D surface characteristics of additively manufactured metal alloys and their impacts on fatigue life of components made by additive…

This $108,218 Cooperative Agreement from the National Institute of Standards and Technology's Measurement and Engineering Research and Standards program will fund research at the Colorado School of Mines to characterize additive manufacturing surfaces and develop predictive fatigue models. Over an 18-month period ending September 2023, the research team will conduct experiments to better understand surface formation in metal alloys produced via additive manufacturing. They will also perform 3D surface characterization and develop a material-independent approach for predicting fatigue performance of as-built components with rough surfaces fabricated through additive manufacturing. The research aims to improve understanding of additive manufacturing surfaces and fatigue behavior, leading to better measurement methods and qualification tools that will benefit U.S. aerospace and medical device industries through reduced costs and improved products. No subawards are planned under this Cooperative Agreement.

Activities

This research project will focus on characterization and analysis of four commonly used metal am materials. This research will be broken into three tasks. Task 1 is to perform experiments and analysis leading to better understanding of surface formation in the alloy systems. Task 2 involves the 3D surface characterization of the am surfaces. Task 3 is to develop a predictive model for fatigue performance.

Expected outcomes

The research conducted in this project will lead to a material independent approach for understanding the processing-structure-properties-performance relationship for the fatigue performance of as-built components with rough surfaces fabricated through am. Improved understanding of am surfaces and fatigue performance will lead to better measurement methods for surface characterization to be developed, leading to rapid qualification tools for additively manufactured mission critical components.

Intended beneficiaries

The research conducted under this proposal will support graduate students at the colorado school of mines to do advanced research in surface characterization of additively manufactured parts in a cooperative manner with NIST. Colorado school of mines faculty and graduate students will benefit from NIST resources and expertise in metal-based additive manufacturing. The research will be of significant value to the public by providing research results of surface characteristics of additively manufactured super alloys and their effects on fatigue life of such parts under high stress conditions. Such applications provide significant benefit to U.S. Aerospace and medical device industries to reduce cost and improve products.

Subrecipient activities

The recipient does not intend to subaward funds.