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Book Chapter
Defects in Metal Additive Manufacturing Processes
Available to PurchaseSeries: ASM Handbook
Volume: 24
Publisher: ASM International
Published: 15 June 2020
DOI: 10.31399/asm.hb.v24.a0006557
EISBN: 978-1-62708-290-7
... Abstract The formation of defects within additive-manufactured (AM) components is a major concern for critical structural and cyclic load applications. Thus, understanding the mechanisms of defect formation in fusion-based processes is important for prescribing the appropriate process...
Abstract
The formation of defects within additive-manufactured (AM) components is a major concern for critical structural and cyclic load applications. Thus, understanding the mechanisms of defect formation in fusion-based processes is important for prescribing the appropriate process parameters specific to the alloy system and selected processing technique. This article discusses the formation of defects within metal additive manufacturing, namely fusion-based processes and solid-state/sintering processes. Defects observed in fusion-based processes include lack of fusion, keyhole collapse, gas porosity, solidification cracking, solid-state cracking, and surface-connected porosity. The types of defects in solid-state/sintering processes are sintering porosity and improper binder burnout. The article also discusses defect-mitigation strategies, such as postprocess machining, surface treatment, and postprocessing HIP to eliminate defects detrimental to properties from the as-built condition. The use of noncontact thermal, optical, and ultrasound techniques for inspecting AM components are also considered. The final section summarizes the knowledge gap in our understanding of the defects observed within AM components.
Book Chapter
Process Defects in Metal Additive Manufacturing
Available to PurchaseSeries: ASM Handbook
Volume: 24A
Publisher: ASM International
Published: 30 June 2023
DOI: 10.31399/asm.hb.v24A.a0006972
EISBN: 978-1-62708-439-0
... Abstract This article presents a general understanding of causes and possible solutions for defects in the most common metal additive manufacturing (AM) processes: laser powder-bed fusion (L-PBF), laser directed-energy deposition (DED-L), and binder jetting (BJ). additive manufacturing...
Abstract
This article presents a general understanding of causes and possible solutions for defects in the most common metal additive manufacturing (AM) processes: laser powder-bed fusion (L-PBF), laser directed-energy deposition (DED-L), and binder jetting (BJ).
Image
Common defects present in components fabricated by additive manufacturing. ...
Available to Purchase
in Introduction to Materials and Processes for Additive Manufacturing/Alloy Design and Materials Selection
> Additive Manufacturing Design and Applications
Published: 30 June 2023
Fig. 5 Common defects present in components fabricated by additive manufacturing. (a) Porosity. (b) Lack of fusion. (c) Solidification cracking. Source: Ref 22
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Series: ASM Handbook
Volume: 20
Publisher: ASM International
Published: 01 January 1997
DOI: 10.31399/asm.hb.v20.a0002440
EISBN: 978-1-62708-194-8
... information on the legal bases for products liability and definitions for two types of defects: manufacturing defects and design defects. It summarizes other possible defects in design as well as preventive measures. design defects manufacturing defects product design product liability PRODUCTS...
Abstract
Products liability is a legal term for the action whereby an injured party (plaintiff) seeks to recover damages for personal injury or property loss from a producer and/or seller when the plaintiff alleges that a defective product caused the injury or loss. This article provides information on the legal bases for products liability and definitions for two types of defects: manufacturing defects and design defects. It summarizes other possible defects in design as well as preventive measures.
Book Chapter
Maintainability Issues
Available to PurchaseBook: Composites
Series: ASM Handbook Archive
Volume: 21
Publisher: ASM International
Published: 01 January 2001
DOI: 10.31399/asm.hb.v21.a0003456
EISBN: 978-1-62708-195-5
... the considerations for maintainability of the composite structures during the conceptual design phase. Sources of the defects and damage, such as manufacturing defects and in-service defects, are reviewed. The article describes the nondestructive inspection methods that are used in the repair of composite structures...
Abstract
Maintainability is a function of the durability, damage tolerance, and repairability of a structure. This article discusses the configurations of composite structures, such as sandwich, stiffened-skin, and monolithic structures, used in commercial aircraft composites. It describes the considerations for maintainability of the composite structures during the conceptual design phase. Sources of the defects and damage, such as manufacturing defects and in-service defects, are reviewed. The article describes the nondestructive inspection methods that are used in the repair of composite structures to locate damage, characterize the extent of damage, and ensure post-repair quality. It lists suggestions that can be used as design guidelines for adhesive bonding, general composite structure, sandwich structure, material selection, and lightning-strike protection. The article also provides the basic considerations for personnel, facilities, and equipment during maintenance.
Book Chapter
Fracture and Fractography of Elastomeric Materials
Available to PurchaseSeries: ASM Handbook
Volume: 11B
Publisher: ASM International
Published: 15 May 2022
DOI: 10.31399/asm.hb.v11B.a0006870
EISBN: 978-1-62708-395-9
... Abstract This article examines the concept of fractography as applied to elastomeric rubbery materials. It considers four general categories of physical root failure causes: design defects, material defects, manufacturing defects, and service life anomalies. Examples of real-world failures...
Abstract
This article examines the concept of fractography as applied to elastomeric rubbery materials. It considers four general categories of physical root failure causes: design defects, material defects, manufacturing defects, and service life anomalies. Examples of real-world failures of rubber articles, with numerous accompanying figures, are representative of the four root failure categories.
Book: Composites
Series: ASM Handbook Archive
Volume: 21
Publisher: ASM International
Published: 01 January 2001
DOI: 10.31399/asm.hb.v21.a0003467
EISBN: 978-1-62708-195-5
... deal mainly with structures that exhibit an initial material and/or manufacturing defect or failures that are most prevalent and most easily solved. The components include helicopter rotor blade, composite wing spar, and aircraft rudder. aircraft rudders composite wing spar helicopter rotor...
Abstract
This article describes the results of several case history studies of the failure of polymer-matrix composite components to provide not only some representative types of failures that can encounter, but also to provide some insight into the investigative process. These case histories deal mainly with structures that exhibit an initial material and/or manufacturing defect or failures that are most prevalent and most easily solved. The components include helicopter rotor blade, composite wing spar, and aircraft rudder.
Book Chapter
Properties Needed for the Design of Static Structures
Available to PurchaseSeries: ASM Handbook
Volume: 20
Publisher: ASM International
Published: 01 January 1997
DOI: 10.31399/asm.hb.v20.a0002468
EISBN: 978-1-62708-194-8
... the estimation of probability of failure with an example. It reviews the designing and selection of materials for static strength and stiffness. The article also describes the causes of failure of engineering components, including design deficiencies, poor selection of materials, and manufacturing defects...
Abstract
This article provides a schematic illustration of factors that should be considered in component design. It discusses the effect of component geometry on the behavior of materials and groups the main parameters that affect the value of the factor of safety. The article illustrates the estimation of probability of failure with an example. It reviews the designing and selection of materials for static strength and stiffness. The article also describes the causes of failure of engineering components, including design deficiencies, poor selection of materials, and manufacturing defects.
Image
Additively manufactured Ti-6Al-4V bracket; (a) no defects shown, (b) exampl...
Available to Purchase
in X-Ray—Radiography and Computed Tomography in Additive Manufacturing
> Additive Manufacturing Design and Applications
Published: 30 June 2023
Fig. 1 Additively manufactured Ti-6Al-4V bracket; (a) no defects shown, (b) examples of 2D x-ray radiographic images
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Book Chapter
Failure Analysis of Railroad Components
Available to PurchaseSeries: ASM Handbook
Volume: 11A
Publisher: ASM International
Published: 30 August 2021
DOI: 10.31399/asm.hb.v11A.a0006837
EISBN: 978-1-62708-329-4
... and manufacturing defects has become more important. This article presents case histories that are intended as an overview of the unique types of failures encountered in the freight railroad industry. The discussion covers failures of axle journals, bearings, wheels, couplers, rails and rail welds, and track...
Abstract
Because of the tough engineering environment of the railroad industry, fatigue is a primary mode of failure. The increased competitiveness in the industry has led to increased loads, reducing the safety factor with respect to fatigue life. Therefore, the existence of corrosion pitting and manufacturing defects has become more important. This article presents case histories that are intended as an overview of the unique types of failures encountered in the freight railroad industry. The discussion covers failures of axle journals, bearings, wheels, couplers, rails and rail welds, and track equipment.
Series: ASM Handbook Archive
Volume: 11
Publisher: ASM International
Published: 01 January 2002
DOI: 10.31399/asm.hb.v11.a0003505
EISBN: 978-1-62708-180-1
... Abstract This article discusses the three legal theories on which a products liability lawsuit is based and the issues of hazard, risk, and danger in the context of liability. It describes manufacturing and design defects of various products. The article explains a design that is analyzed from...
Abstract
This article discusses the three legal theories on which a products liability lawsuit is based and the issues of hazard, risk, and danger in the context of liability. It describes manufacturing and design defects of various products. The article explains a design that is analyzed from the human factors viewpoint and details the preventive measures of the defects, with examples. It presents four paramount questions relating to the probability of injury which are asked even when one executes all possible preventive measures carefully and thoroughly.
Image
OM image (left) and SEM images (middle and right) showing fracture surfaces...
Available to PurchasePublished: 01 June 2024
is predominantly oriented parallel to the fracture plane. Significant porosities are manufacturing defects associated with the injection molding process. Original magnification of middle and right images: 16×.
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Book: Composites
Series: ASM Handbook Archive
Volume: 21
Publisher: ASM International
Published: 01 January 2001
DOI: 10.31399/asm.hb.v21.a0003460
EISBN: 978-1-62708-195-5
... due to their low weight and inherent structural stiffness. As these materials continue to be used, it is inevitable for premature failures to occur as a result of manufacturing defects, unexpected loads, environmental exposure, and in-service damage. The need to understand and analyze these failures...
Abstract
This article provides a summary of the concepts discussed in the articles under the Section “Failure Analysis” in ASM Handbook, Volume 21: Composites. Most of the information in this Section is geared toward organic-matrix composites, although there is some information on failure analysis and fractography of ceramic- and metal-matrix composites.
Book Chapter
Nondestructive Testing in Additive Manufacturing—A Review
Available to PurchaseSeries: ASM Handbook
Volume: 24A
Publisher: ASM International
Published: 30 June 2023
DOI: 10.31399/asm.hb.v24A.a0007023
EISBN: 978-1-62708-439-0
... work carried out for developing standards is also included. additive manufacturing defect formation in-process inspection in-process monitoring nondestructive testing Additive Manufacturing Process Categories and Part Quality Additive manufacturing (AM), also known as three...
Abstract
This article covers defect formation and classification, followed by a brief description of the most common nondestructive testing (NDT) methods used for postbuild inspection. Descriptions of the established and emerging NDT techniques for in-process monitoring (IPM) and in-process inspection (IPI) in additive manufacturing (AM) also are provided, highlighting the advantages and limitations. The article concludes with a list of the main NDT methods and techniques used. As qualification and certification of AM parts is an urgent matter for the AM industry, a description of the current work carried out for developing standards is also included.
Book Chapter
Resonant Ultrasound Spectroscopy Testing Methods in Additive Manufacturing
Available to PurchaseSeries: ASM Handbook
Volume: 24A
Publisher: ASM International
Published: 30 June 2023
DOI: 10.31399/asm.hb.v24A.a0006953
EISBN: 978-1-62708-439-0
... obtained with the different RUS systems are shown. Resonant Ultrasound Spectroscopy Tests on Stainless Steel Star Artifacts with Typical Additive Manufactured Defects Description of the Tested Samples Technical Committee 261 of the International Organization for Standardization (ISO) and ASTM...
Abstract
This article presents the basic principle, characteristics, advantages, and disadvantages of resonant ultrasound spectroscopy (RUS) methods in additive manufacturing. It focuses on the two types of RUS methods: the swept-sine method and the impulse excitation method. Representative significant results for additively manufactured complex parts obtained with the different RUS systems are also shown. The article also presents the basic principle and examples of nonlinear RUS methods.
Book Chapter
Application of Machine Learning to Monitor Metal Powder-Bed Fusion Additive Manufacturing Processes
Available to PurchaseSeries: ASM Handbook
Volume: 24A
Publisher: ASM International
Published: 30 June 2023
DOI: 10.31399/asm.hb.v24A.a0006992
EISBN: 978-1-62708-439-0
..., keyhole collapse, lack of fusion, solidification cracking, delamination/warping, and poor surface finish ( Ref 2 , 33 , 34 ). An aggregate list of seven core types of defects in AM, established in Ref 35 , is presented in Table 1 . Defect types in additive manufacturing processes Table 1 Defect...
Abstract
The use of additive manufacturing (AM) is increasing for high-value, critical applications across a range of disparate industries. This article presents a discussion of high-valued engineering components predominantly used in the aerospace and medical industries. Applications involving metal AM, including methods to identify pores and voids in AM materials, are the focus. The article reviews flaw formation in laser-based powder-bed fusion, summarizes sensors used for in situ process monitoring, and outlines advances made with in situ process-monitoring data to detect AM process flaws. It reviews investigations of ML-based strategies, identifies challenges and research opportunities, and presents strategies for assessing anomaly detection performance.
Book Chapter
Effects of Process-Induced Defects on Fatigue Properties of Laser Powder Bed Fusion Metallic Materials
Available to PurchaseSeries: ASM Handbook
Volume: 24A
Publisher: ASM International
Published: 30 June 2023
DOI: 10.31399/asm.hb.v24A.a0006985
EISBN: 978-1-62708-439-0
... manufactured metal parts aluminum alloys fatigue failure laser powder bed fusion nickel-base superalloys process-induced defects titanium alloys Fatigue as a Critical Performance Metric Fatigue failure is a critical performance metric for additively manufactured (AM) metal parts, especially those...
Abstract
Fatigue failure is a critical performance metric for additively manufactured (AM) metal parts, especially those intended for safety-critical structural applications (i.e., applications where part failure causes system failure and injury to users). This article discusses some of the common defects that occur in laser powder bed fusion (L-PBF) components, mitigation strategies, and their impact on fatigue failure. It summarizes the fatigue properties of three commonly studied structural alloys, namely aluminum alloy, titanium alloy, and nickel-base superalloy.
Book Chapter
Nondestructive Evaluation of Additively Manufactured Metallic Parts
Available to PurchaseSeries: ASM Handbook
Volume: 17
Publisher: ASM International
Published: 01 August 2018
DOI: 10.31399/asm.hb.v17.a0006465
EISBN: 978-1-62708-190-0
... Abstract Additive manufacturing (AM) is the process of joining materials to make parts from three-dimensional (3D) model data, usually layer upon layer, as opposed to subtractive manufacturing and formative manufacturing methodologies. This article discusses various defects in AM components...
Abstract
Additive manufacturing (AM) is the process of joining materials to make parts from three-dimensional (3D) model data, usually layer upon layer, as opposed to subtractive manufacturing and formative manufacturing methodologies. This article discusses various defects in AM components, such as porosity, inclusions, cracking, and residual stress, that can be avoided by using vendor recommended process parameters and approved materials. It describes the development of process-structure-property-performance modeling. The article explains the practical considerations in nondestructive evaluation for additively manufactured metallic parts. It also examines nondestructive testing (NDT) inspection and characterization methods for each of the manufacturing stages in their natural order. The article provides information on various inspection techniques for completed AM manufactured parts. The various electromagnetic and eddy current techniques that can be used to detect changes to nearsurface geometric anomalies or other defects are also discussed. These include ultrasonic techniques, radiographic techniques, and neutron imaging.
Book Chapter
The Role of the Engineering Expert in Product Liability Litigation
Available to PurchaseSeries: ASM Handbook
Volume: 11A
Publisher: ASM International
Published: 30 August 2021
DOI: 10.31399/asm.hb.v11A.a0006832
EISBN: 978-1-62708-329-4
.... The plaintiff in such a case alleges that the product is defective and presented an unreasonable risk of harm when being used as intended. Depending on the issues, all parties in the chain of commerce of a product, including the manufacturer of raw materials, component manufacturer, assembling manufacturer...
Abstract
The purpose of this article is to assist the reader in understanding the role that an engineering expert witness plays in evaluating incidents related to product liability, so that he or she may become better acquainted with the role that an engineer plays in such litigation. The topics covered are admissibility of expert opinions, how to evaluate data, factual evidence, mandatory and voluntary standards, physical evidence, medical records, scientific literature, design decisions evaluation, environment of use, user's contribution, reports of opposing experts, report of findings, and deposition and trial testimonies.
Book Chapter
Hot Isostatic Pressing for Metal Additive Manufacturing
Available to PurchaseSeries: ASM Handbook
Volume: 24
Publisher: ASM International
Published: 15 June 2020
DOI: 10.31399/asm.hb.v24.a0006552
EISBN: 978-1-62708-290-7
..., economics, and advantages of the process. The discussion also covers the use of HIP for additively manufactured material to eliminate internal defects, the HIP parameters required to eliminate internal defects, and the influence of HIP on the microstructure and properties of HIP additively manufactured...
Abstract
Hot isostatic pressing (HIP) is widely used within the additive manufacturing (AM) industry to improve material performance and ensure quality. This article is a detailed account of the HIP process, providing information on its equipment set up and discussing the applications, economics, and advantages of the process. The discussion also covers the use of HIP for additively manufactured material to eliminate internal defects, the HIP parameters required to eliminate internal defects, and the influence of HIP on the microstructure and properties of HIP additively manufactured material.
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