Boeing

PBF Build Process Interruption Study - Phase 2 Fatigue Study

The existing UW Round Robin focuses on EOS M290 intra-build, intra-machine, and inter-machine variation study in both static and fatigue material behavior. The study is supported by industrial members and FAA. With the project progress in 2020 and 2021, there are ideas about where these variations may come from. With the existing UW Round Robin study transition into fatigue focus and literature studies, performance variation exists and many studies are in place to further understand the variation sources. Besides typical process parameter studies, the effects on the process/ machine induced build variation is yet to be well understood. By using Round Robin data, it greatly reduces the amount of preparation and design of experiment time, allowing students to focus on one of the key interests in variation factor. The data received from the interruptions study will continue to support production non-conformance decision. This student team worked to leverage the existing DoE design in Round Robin study and design interruptions in the build process and study its material behavior tolerance on various interruptions. Anticipated deliverables included: • For the interruption design, this student team will work to design interruption locations and degreed of the interruptions • This student team will work to identify effects on fatigue performance for machined coupons with and without HIP • This student team will work to create documentation on the surface variations in as printed condition • This student team will work to understand defect characterization via NDE such as SEM and Micro-CT