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Additively manufacturing tantalum is a challenging process in which obstacles are stemming from the high melting temperature and susceptibility to oxidation of tantalum. Several combinations of deposition parameters were considered in an effort to obtain fully dense additively manufactured tantalum produced on an EOSINT M280 DMLS system. Deposition parameters significantly affect the resulting microstructure of additively manufactured tantalum, altering grain morphology, grain size, crystallographic preferred orientation, and deposition porosity. Due to the nature of the laser sintering process applied, which implies large directional temperature gradients, the resulting microstructures were strongly columnar along the building direction. Microstructural differences for different deposition conditions manifested themselves in both grain morphology and preferred crystal orientations in the columnar grains. Deposition speed and laser power were important parameters to consider for obtaining porosity-free material. Stripe width had the most significant effect on grain growth.

Recent work in both 304L and 316L stainless steel produced by additive manufacturing (AM) has shown that in addition to the unique, characteristic microstructures formed during the process, a fine dispersion of sub-micron particles, with a chemistry different from either the powder feedstock or the expected final material, are evident in the final microstructure. Such fine-scale features can only be resolved using transmission electron microscopy (TEM) or similar techniques. The present work uses electron microscopy to study both the initial powder feedstock and microstructures in final AM parts. Special attention is paid to the chemistry and origin of these nanoscale particles in several different metal alloys, and their impact on the final build. Comparisons to traditional, wrought material will be made.

Irradiations were performed with 1.5 MeV protons to 0.6 dpa at 40–150 °C on additively manufactured (AM) 304L stainless steel and the changes in microstructure and mechanical behavior after irradiation were compared to wrought 304L stainless steel. All microstructural and hardness results after irradiation suggest the samples evolve toward a similar state, despite significant differences in the unirradiated microstructures and hardness values. A TEM and nanoindentation-based investigation of before and after proton irradiation at 40–150 °C is presented. Results are interpreted in terms of initial dislocation content, dislocation structures, and microstructural and chemical homogeneity.

Certification and product qualification of an engineering component generally involves meeting engineering and physics requirements tied to its functional requirements.. In this paper, the results of a study quantifying the microstructure and the dynamic damage evolution of Tantalum (Ta) fabricated using an EOS laser-powder-bed machine are presented. The microstructure of the AM-Ta is detailed and compared / contrast to wrought Ta. The dynamic damage evolution and failure response of the AM-Ta material, as well as wrought Ta, was probed using flyer-plate impact driven spallation experiments. The differences in the spallation response between the AM and wrought Ta were measured using in-situ velocimetry as well as post-mortem quantification of damage in “soft-recovered” samples. The damage evolution of the AM and wrought Ta were characterized using optical metallography.

For additive manufacturing (AM) of metallic materials, the certification and qualification paradigm needs to evolve as there currently exists no broadly accepted “ASTM- or DIN-type” additive manufacturing certified process or AM-material produced specifications. Accordingly, design, manufacture, and thereafter implementation and insertion of AM materials to meet engineering applications requires detailed quantification of the constitutive (strength and damage) properties of these evolving materials, across the spectrum of metallic AM methods, in comparison/contrast to conventionally-manufactured metals and alloys. This report summarizes the 316L SS research results and presents initial results of the follow-on study of 304L SS. For the AM-316L SS investigation, cylindrical samples of 316L SS were produced using a LENS MR-7 laser additive manufacturing system from Optomec (Albuquerque, NM) equipped with a 1kW Yb-fiber laser. The microstructure of the AM-316L SS was characterized in both the “as-built” Additively Manufactured state and following a heat-treatment designed to obtain full recrystallization to facilitate comparison with annealed wrought 316L SS. The dynamic shock-loading-induced damage evolution and failure response of all three 316L SS materials was quantified using flyer-plate impact driven spallation experiments at peak stresses of 4.5 and 6.35 GPa. The results of these studies are reported in detail in the first sectionmore » of the report. Publication of the 316L SS results in an archival journal is planned. Following on from the 316L SS completed work, initial results on a study of AM 304L SS are in progress and presented herein. Preliminary results on the structure/dynamic spallation property behavior of AM-304L SS fabricated using both the directed-energy LENS and an EOS powder-bed AM techniques in comparison to wrought 304L SS is detailed in this Level 2 Milestone report.« less

For Certification and qualification of an engineering component generally involves meeting engineering and physics requirements tied to its functional requirements. In this paper, the results of a study quantifying the microstructure, mechanical behavior, and the dynamic damage evolution of Tantalum (Ta) fabricated using an EOS laser-powder-bed machine are presented. The microstructure and quasi-static mechanical behavior of the AM-Ta is detailed and compared / contrasted to wrought Ta. The dynamic damage evolution and failure response of the AM-Ta material, as well as wrought Ta, was probed using flyer-plate impact driven spallation experiments. The differences in the spallation response between the AM and wrought Ta were measured using in-situ velocimetry as well as post-mortem quantification of damage in “soft-recovered” samples. The damage evolution of the AM and wrought Ta were characterized using both optical metallography and electron-backscatter diffraction.