Thin-walled 3D-printed structures in fatigue loaded components

Important results from the project

The project´s aim was to increase confidence in additively manufactured thin-walled components through increased knowledge of distortions, surface finish and microstructure, and to use that knowledge in the development of methodology to determine cross-sectional area and mechanical testing of thin-walled test pieces. Thin-walled components and test rods have been characterized with respect to distortions, surface, microstructure and various methods to determine cross-sectional area have then been used. Some of the methods can be developed further.

Expected long term effects

The goal of the project to develop knowledge about thin-walled components and to develop methods to estimate the cross-sectional area of these. In the long run, these methods will be able to be developed further. A fully developed method would make it easier for e.g. quality control of mechanical properties where test rods in printed condition can be tested directly without further processing, which means lower costs and lead times. Thin-walled components can then be used with greater confidence, which would mean weight reduction and lower material consumption.

Approach and implementation

The project has characterized additively manufactured thin-walled components and test rods and developed methods to estimate the cross-sectional area of these, with aim of increasing confidence in the use of thin-walled components. A material has been characterized continuously through the entire chain from printing to heat treatment to mechanical testing, where a cross-sectional area estimation method is used. This method was compared against results from X-ray tomography and optical microscopy.