Shear Testing Additively Manufactured Metal Specimens
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Solution Overview
Problem
Current tensile testing methods for additively manufactured metal specimens are inefficient due to the time-consuming process of fabricating and handling test coupons, which requires significant resources and space, and does not effectively utilize machine learning for optimization.
Innovation Solution
High-speed shear testing of metal specimens built directly on a build plate, using a bridging member with support members, where load, displacement, and strain values are measured and extrapolated to estimate tensile properties using a plastic yield surface criterion, combined with machine learning to optimize manufacturing parameters.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If traditional tensile testing methods are used with independently fabricated test coupons, then accurate tensile strength measurements can be obtained, but the testing process becomes time-consuming and resource-intensive
Solution Approach 1:
The patent merges the test specimen fabrication and testing processes by integrating specimens directly onto the build plate during additive manufacturing. Multiple specimens are built simultaneously on a single build plate and tested in place, eliminating the need for separate fabrication and handling steps. This combining of operations dramatically reduces testing time while maintaining measurement accuracy through direct integration of the specimen in its final configuration.
Solution Approach 2:
The patent performs preliminary actions by fabricating multiple test specimens on the build plate during the additive manufacturing process itself, before the actual mechanical testing occurs. The specimens are pre-positioned and prepared in their final testing configuration during the build process, eliminating post-manufacturing handling and setup time. This preliminary preparation enables rapid sequential testing without repeated fabrication cycles.
2Quantity of substance
If multiple independent test coupons are fabricated for tensile testing, then sufficient material testing can be performed, but significant amounts of expensive powder and build plate space are consumed
Solution Approach 1:
The patent merges multiple specimen fabrication operations into a single additive manufacturing process. Multiple test specimens are built simultaneously on the same build plate using the same powder supply, sharing the build plate space and material resources. This consolidates what would otherwise require multiple separate fabrication operations, reducing total powder consumption and build plate usage while increasing the number of specimens that can be tested.
Solution Approach 2:
The build plate serves multiple functions simultaneously: it acts as the substrate for additive manufacturing and as the testing fixture for mechanical testing. The same build plate structure supports multiple specimens during both fabrication and subsequent testing operations. This multi-functionality eliminates the need for separate specimen holders or additional build plates, maximizing resource utilization and reducing material waste.
3Reliability
If traditional tensile testing with operator handling is used, then proper specimen placement and testing can be ensured, but operator time and manual intervention are required
Solution Approach 1:
The patent implements self-service by designing specimens that are self-contained and self-supported on the build plate structure. The specimens maintain their positioning and structural integrity without requiring external handling or operator intervention during testing. The build plate itself serves as the fixture, eliminating the need for manual specimen placement and securing operations. This self-service approach maintains testing reliability through consistent, repeatable positioning while achieving full automation.
4Measurement precision
If conventional tensile testing procedures are followed, then comprehensive mechanical properties can be measured, but the process requires significant time and resources
Solution Approach 1:
The patent enables continuous useful action by eliminating idle time between specimen fabrication and testing. Specimens are fabricated continuously during additive manufacturing operations, then immediately tested in sequence on the same build plate without interruption or repositioning. This continuous workflow removes the discontinuities inherent in traditional methods where specimens must be removed, handled, and repositioned between fabrication and testing, dramatically reducing total cycle time while maintaining measurement accuracy.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach significantly reduces testing time and costs, allows for rapid screening of mechanical properties, and enables the use of machine learning for further optimization of the parameter space, improving the accuracy and efficiency of metal additive manufacturing.
Implementation Method 1
The most popular AM processes for metals include laser beam melting, electron beam melting, and laser beam deposition
Implementation Method 2
a particular type of AM process uses an energy beam, for example, an electron beam or electromagnetic radiation such as a laser beam, to thermally create each layer of the article
Implementation Method 3
the metal powder or wire is subjected to a complex thermal cycle that includes rapid heating above the melting temperature of the respective metal due to energy absorption from the laser (or electron beam) and its subsequent transformation into heat to form a molten metal followed by rapid solidification
Implementation Method 4
High-speed shear testing of metal specimens built directly on a build plate, using a bridging member with support members, where load, displacement, and strain values are measured
Data Source
AI summary
A process for estimating tensile properties associated with a metal additive manufactured component is disclosed. The process includes building ductile metal specimen samples layer-by-layer on a build plate by additive manufacturing, wherein each of the metal specimen samples includes at least one support member and a bridging member spanning a space defined by the at last one support member, wherein the bridging member includes an upper portion that is raised relative to top planar surfaces of the at least one support member, and a lower portion integrally bridging the space defined by the at least one support member and raised relative to the build plate. The process includes sequentially shear testing each of the plurality of specimen samples on the build plate by applying a load to the upper portion of the bridging member and measuring load, displacement and/or local strain values. The process also includes estimating tensile properties by extrapolating the load, displacement and/or local strain values obtained from the shear testing based on a plastic yield surface criterion.