<p>Additively manufactured parts, in spite of their many advantages, face substantial challenge on the path towards certification. This challenge is more pronounced in the quality-demanding aviation industry, where the safety considerations are paramount. A major reason for this challenge is the lack of history associated with AM built parts compared to the traditional cast and wrought components. In assessing structural integrity of cast and wrought components, material properties obtained from laboratory coupon tests are routinely applied for design calculation of large components. However, for AM parts, questions remain over transferability of properties over multiple length scales due to possible variations in material chemistry, microstructure and defect. In this work, this issue is investigated by conducting mechanical tests on simple lugs of nickel-based super-alloys. The lugs are produced by the laser powder bed fusion process. After appropriate heat treatment and machining operations, the lugs are subjected to strength, low cycle fatigue and crack propagation tests. Multiple tests are carried out in order to assess repeatability. Finally calculations are performed to assess whether the test results can be predicted with standard design methods. The obtained results generate confidence in predictable, repeatable behavior of the AM built lugs. Continuation of this approach over larger length scales has the potential to build enough confidence so that additively manufactured parts can be used in load-bearing structural elements of the aircraft engine.</p>

Mechanical Testing of Additively Manufactured Super-Alloy Lugs

Paper Proceedings: https://asmedigitalcollection.asme.org/GT/GT2021/volume/84898

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