Recommended Protocol for Round Robin Studies in Additive Manufacturing.

One way to improve confidence and encourage proliferation of additive manufacturing (AM) technologies and parts is by generating more high quality data describing the performance of AM processes and parts. Many in the AM community see round robin studies as a way to generate large data sets while distributing the cost among the participants, thereby reducing the cost to individual users. The National Institute of Standards and Technology (NIST) has conducted and participated in several of these AM round robin studies. While the results of these studies are interesting and informative, many of the lessons learned in conducting these studies concern the logistics and methods of the study and unique issues presented by AM. Existing standards for conducting interlaboratory studies of measurement methods, along with NIST's experience, form the basis for recommended protocols for conducting AM round robin studies. The role of round robin studies in AM qualification, some of the limitations of round robin studies, and the potential benefit of less formal collaborative experiments where multiple factors, AM machine being only one, are varied simultaneously are also discussed.

Interlaboratory study for nickel alloy 625 made by laser powder bed fusion to quantify mechanical property variability.

Six different organizations participated in this interlaboratory study to quantify the variability in the tensile properties of Inconel 625 specimens manufactured using laser-powder-bed-fusion additive manufacturing machines. The tensile specimens were heat treated and tensile tests conducted until failure. The properties measured were yield strength, ultimate tensile strength, elastic modulus, and elongation. Statistical analysis revealed that between-participant variability for yield strength, ultimate tensile strength, and elastic modulus values were significantly higher (up to 4 times) than typical within-participant variations. Only between-participant and within-participant variability were both similar for elongation. A scanning electron microscope was used to examine one tensile specimen for fractography. The fracture surface does not have many secondary cracks or other features that would reduce the mechanical properties. In fact, the features largely consist of microvoid coalescence and are entirely consistent with ductile failure.

The relationships between femoral cortex geometry and tissue mechanical properties.

Bone tissue and geometry are constantly modified through modeling and remodeling at the periosteal, endosteal and intracortical envelopes. Results from several studies indicate that femoral bone geometry is a predictor of whole bone strength (e.g. femoral neck strength), however, it is not known whether there is a relationship between bone structural and material properties. Bone geometry can be determined from parameters based on plane X-ray radiogrammetry which are used to evaluate femoral bone quality for implant success. If there is a relationship between these parameters and tissue mechanical properties, this would have implications in the interpretation of such parameters for assessment of fracture risk and in further understanding of bone biology. Following measurement of radiogrammetric parameters from antero-posterior and medio-lateral X-rays (cortical thickness, bone diameter, bone area, moment of inertia, cortical index, Singh index), human femurs were machined into standard test specimens for assessment of tensile fracture toughness (GIc) of the tissue. Results indicated that tensile fracture toughness generally increased with increasing bone size. We also found that fracture toughness of the tissue was significantly related to radiogrammetric indices and that some of these indices explained a greater variability in toughness than porosity, age or gender.

Time-dependent circumferential deformation of cortical bone upon internal radial loading.

Short and long duration tests were conducted on hollow femoral bone cylinders to study the circumferential (hoop) creep response of cortical bone subjected to an intramedullary radial load. It was hypothesized that there is a stress threshold above which nonlinear creep effects dominate the mechanical response and below which the response is primarily determined by linear viscoelastic material properties. The results indicate that a hoop stress threshold exists for cortical bone, where creep strain, creep strain rate and residual strain exhibited linear behavior at low hoop stress and nonlinear behavior above the hoop stress threshold. A power-law relationship was used to describe creep strain as a function of hoop stress and time and damage morphology was assessed.