Elastic Residual Strain Measurements of 3D Additively Manufactured Builds of Nickel Alloy 718 AM Bench 2022 Artifacts Using Energy Dispersive Synchrotron X-ray Diffraction

Residual elastic strains and the resulting stresses are key aspects of most metal additive manufacturing (AM) approaches and strongly affect both the build process and part performance. Computational modeling of these stresses allows the manufacturer to compensate for the distortions that occur during the build process and to predict where part failures may occur. Such simulations must be validated against rigorous measurement datasets. Here, energy dispersive synchrotron X-ray diffraction is used to characterize the location-specific elastic strains within additively manufactured laser powder bed fusion (PBF-LB) nickel Alloy 718 test artifacts. Elastic strains are measured along two orthogonal directions from 2248 measurement locations and the measurement uncertainties are assessed. Comparisons are made between the measurement results and modeling predictions submitted by the AM modeling community. These measurements are part of the Additive Manufacturing Benchmark Test Series (AM Bench), a broad effort to produce measurement datasets for validating AM computer simulations across the range of processing, structure, and properties, for many AM build methods and material classes. All the measurement data are available online with download links at www.nist.gov/ambench.