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Meeting 2023 Annual International Solid Freeform Fabrication Symposium (SFF Symp 2023)
Symposium 2023 Annual International Solid Freeform Fabrication Symposium (SFF Symp 2023)
Presentation Title Improving Fatigue Performance of PBF Metals using Self-terminating Etching Processes
Author(s) Subbarao Raikar, Steven DiGregorio, Owen Hildreth
On-Site Speaker (Planned) Owen Hildreth
Abstract Scope The poor surface finish of Ti-6Al-4V (Ti64) and GRCop42 parts fabricated from Powder Bed Fusion has detrimental effects on their fatigue performance. With the help of post-processing techniques, the surface finish needs to be improved before the parts are operation ready for better fatigue performance. Self-terminating etching process (STEP) is one such post-processing technique that decreases the surface roughness by as much as 8× and increases the fatigue life by 340% compared to as-printed specimens for Ti64. In this work, we study the fatigue performances of Ti64 using sulfur-based STEP and GRCop42 using iodine-based STEP for surface finishing. The PBF specimens are studied in as-printed, stress-relieved, and post-STEP conditions by characterizing the surface roughness and microstructure.
Proceedings Inclusion? Definite: Post-meeting proceedings

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Microtensile Analysis of Additively Manufactured Ti–6Al–4V with Process Parameter Induced Defects
Mining Complex Feedstock-Geometry-Process-Quality Relationships for Powder Bed Fusion Thin Features using Graphical Model
Modeling and Correcting Illumination Inhomogeneity over Multiple DLP Illumination Intensities for Better Fabrication Accuracy
Modeling and Simulation of Vat Photopolymerization Additive Manufacturing: A Review
Modeling Carbon Fiber Suspension Dynamics for Additive Manufacturing Polymer Melt Flows
Modeling Morphological Development of Ti-6Al-4V for Cyclic Thermal Histories in Laser Powder-bed Fusion
Modifying Glass Surface Morphology via Temperature-controlled Laser Melting
Molybdenum Trioxide (MoO3) Nanosheets Imbedded Carbon Nanofibers for Lithium-ion Batteries
Monitoring of Process Stability in Laser Wire Directed Energy Deposition using Machine Vision
Monitoring of Process Stability in Laser Wire Directed Energy Deposition using Machine Vision
Monitoring of Single-track Quality in Laser Powder Bed Fusion using In-situ Thermionic Sensing
Monitoring of Single-track Quality in Laser Powder Bed Fusion using In-situ Thermionic Sensing
Multi-bead and Multilayer Printing Geometric Defect Identification Using Single Bead Trained Models
Multi-laser Diode Area Melting of Ti6Al4V: A Novel Alternative Approach to Traditional Laser Powder Bed Fusion
Multi-load Support Optimization for Minimizing Part Deformation in LPBF
Multi-material Design in Metal Additive Manufacturing
Multi-physics Modeling of Low-temperature Directed Energy Deposition of Stainless Steel 316L
Multimodal Process Monitoring to Predict Outcomes during Laser Powder Bed Fusion
Nanoparticle-modification of NiCu-based Alloy 400 for Laser Powder Bed Fusion
NASA Technology Maturation Plan for In-space Manufacturing of Metals
Non-linear Dynamic Modelling of Cartesian-frame FFF 3-D Printer Gantry for Predictive Control
Novel Concepts to Integrate Dense and Sparse Infill Regions in Material Extrusion AM Parts
Novel Welding Strategies in High Deposition Rate Laser-Assisted Double-Wire Welding Process with Nontransferred Arc
NSF Advanced Manufacturing Program and Funding Opportunities
Numerical and Experimental Investigations on Manufacturability of Al-Si-10Mg Thin Wall Structures Made by LB-PBF
Numerical Investigation of the Spreading and Dynamic Flow Behavior of Poorly Sorted Sand Particles during Binder Jet Additive Manufacturing
Off the Grid: Re-defining Design Resolution in Inkjet 3D-printing for Sub-droplet Position Control and Facile Geometry Improvement
On Process Stability In WAAM-CMT of Aluminum Alloys
On the Effect of Recoater Damage on Spreading Behavior
Open Architecture Control Software for Laser Powder Bed Fusion Machines
Open Loop Control of Selective Laser Flash Sintering of Ceramics
OpenVCAD: An Open Source Volumetric Multi-material Geometry Compiler
Optical Metrology for Laser-matter Interaction in LPBF: Challenges and Opportunities
Optimal Planning and Control for Microhardness Demonstrated in Thin-walled Steel Parts Made via Wire Arc Additive Manufacturing
Optimization of Computational Time for Digital Twin Database in Directed Energy Depostion for Residual Stresses
Optimizing the Surface Texture and Chemistry of Laser Powder Bed Fusion (LPBF) Haynes 282 for Increased Solar Absorptance
Origami Robocasting of High-density Ceramic Structures with Slurry-based Inks
Out-of-plane Mechanical Properties of Additively Manufactured Fractal Reinforced Structures
Oxide Dispersion Strengthened (ODS) SS316L Prepared by Laser Powder Bed Fusion: Analysis of Microstructure and Hardness Properties
Parametric Analyses of Impact of Deposition Pressure on Multi-axis Free-form Fabrication.
Parametric Study of Processing of Ti6Al4V with Multiple 450 nm Diode Lasers
Part Scale Simulation of Heat Affected Zones for Parameter Optimization in a Microscale Selective Laser Sintering System
Path Planning for Non-Planar Robotic Additive Manufacturing
PEEK Parameter Optimization for Fused Deposition Modeling
Photoinhibition Aided Vat Photopolymerization (PinVPP) Additive Manufacturing
Photothermal Bleaching of Nickel Dithiolene for Bright Multi-colored 3D Printed Parts
Physical Validation of Job Placement Optimization in Cooperative 3D Printing
Powder Bed Fusion of Polypropylene-ethylene Co-polymers
Powder Bed Fusion of Ultra-high Molecular Weight Polyethylene via Novel Scan Strategy and Post-process
Powder Bed Fusion Surrogate Models via Convolutional Neural Networks
Predicting Temperature Field for Metal Additive Manufacturing using PINN
Predicting the Printable Parameter Space for Laser Directed Energy Deposition Using a Data Augmented Thermal Model
Prediction of Inter-pass Temperature for Large-scale Double Sided Component Fabricated Electron Beam Wire Additive Manufacturing
Printing Parameter Optimization of Extruded Metal Paste by Response Surface Technique
PRISM: Process Parameter Optimization for Selective Manufacturing
Probing Temperature and Degree-of-conversion States via Tomographic Fluorescence Imaging
Process-integrated Alloy Adjustment in Laser Deposition Welding with Two Wires
Process and Design Strategies for Fluid Wicking in Additively Manufactured Inconel 718 for Monolithic Heat Pipes
Process and Material Optimisations for Integration of Chopped Glass Fibres in Laser Sintered Polymer Parts
Process Modeling for Fluid-Interface Supported Resin Printing
Process Modeling of Multi-Material Laser Powder Bed Fusion
Process Parameter Optimization Using Photodiode Intensity in Laser Powder Bed Fusion
Process Parameters and Interpass Temperature Effects on WAAM Inconel 718
Process Strategy and Geometrical Distortion of Heat-treated 17-4PH Stainless Steel Produced by Interleaved Machining and Blown-powder DED
Process Structure Relationships of Carbide Containing Molybdenum Alloys Produced via Electron Beam Powder Bed Fusion
Providing Anti-counterfeiting Security in Binder Jetting through Tailored Porosity Signatures
Pushing Boundaries: Machine Learning Applied to Selective Laser Melting
Qualification of Low-criticality AM Components in an Expeditionary Environment
Quantification of Residual Stress in Directed Energy Deposition Additive Manufacturing via Bridge Method
Quasistatic Energy Absorption in Aperiodic Cellular Materials
Rapid Foam Foundry: The Future of Foam Foundry
Real-time Image-based Quality Control for Bio-additive Manufacturing through Layer-by-layer Analysis
Real-time Melt Pool Characterization in Laser Powder Bed Fusion Using Acoustic and Photodiode Monitoring
Real-time Monitoring of Directed Energy Deposition Additive Manufacturing Process Using Multiple Sensors and Machine Learning
Real Time Quantification of Shear-induced Molecular Ordering in Direct Write Printing of Bottlebrush Based Polymer Networks
Residual Stress Analysis of Laser Powder Blown Inconel 718 Across Different Overhang Angles and Laser Outputs
Residual Stress Estimation in a Complex Additively Manufactured Component with an Internal State Variable Material Model
Resource Efficiency of the Robot-based Hybrid Additive Manufacturing Chain
Revealing and Controlling Process Instabilities for Defect Lean Metal Additive Manufacturing
Robot-aided selective embedding of a spatially steered fiber in polymer composite parts made using vat photopolymerization
Robotic Automation for Depowdering in Binder Jet Additive Manufacturing
Robotic Wire-fed Additive Manufacturing for Forging Industry.
Role of In-situ Monitoring Technique for Digital Twin Development using Direct Energy Deposition: Melt Pool Dynamics and Thermal Distribution
Self-heating Tooling on BAAM using Co-extruded Heating Wires
Self-repair of Defects: The Achilles Heel for In-process Detection of Small Pores?
Side on Plasma Emission Spectroscopy of TiAl6V4 During Laser Scanning
Simulation Based Optimization for High Frequency Piezo-actuated Molten Metal Droplet Jetting
Simulation of Anisotropic Mechanical Behavior of Additively Manufactured Ti-6Al-4V Wall Structures using VPSC
Single Path Generation for Closed Contours via Graph Theory and Topological Hierarchy
Slurry-based Binder Jetting of Ceramic Casting Cores
SmartScan Extension: Enhancing Temperature Uniformity in 3D Laser Powder Bed Fusion Additive Manufacturing for Reduced Part Defects and Distortions
Solid-state Production of Uniform Metal Powders for Additive Manufacturing by Ultrasonic Vibration Machining
Solidification Behavior, Texture Evolution, and Mechanical Behavior of Large Scale Fusion Additively Manufactured Steels: Interplay Between Chemistry and Unique Processing Conditions
Spreading and Packing of Ceramic Powder Using a Displacement-controlled Roller in SLFS
State-of-the-art Cyber-enabled Physical and Digital Systems Deployed in Distributed Digital Factory Using Additive and Subtractive Manufacturing Systems: Open, Scalable, and Secure Framework
Static Mixing Nozzles for Long and Short Fiber Additive Extrusion Processes
Stimuli Driven Morphing of Printed Liquid Crystal Elastomers
Streaming in Additive Manufacturing: Analyzing the Impact on the Powder Bed Fusion of Metals Process Chain
Strength Enhancement of cellular structures through selective reinforcement of elements based on analytical modeling
Strengthening FFF Parts via Annealing with Structured Dual Material Filaments and Dissolvable High-temperature Shells
Structural Analysis and Design of Mantis Shrimp-inspired Composites for Enhanced Impact Resistance
Structural Stability During Thermal Post-curing of Direct Ink Write Thermoset Composites
Surface Roughness Formation and Measurement for Metals Built with Laser Powder Bed Fusion
System Identification of Fused Filament Fabrication Additive Manufacturing Extrusion and Spreading Dynamics
Tailoring Anisotropic Material Properties of Hierarchical Lattice Structures through Strut Diameter and Orientation Variations: Implications for 3D-printed Ti6Al4V Lattices
Tailoring Mechanical Behaviors through Programmable Lattice Structures
Test Submission for Proceedings
Testing Protocol Development for Fracture Toughness of Parts Built with Big Area Additive Manufacturing
The Detection of Defects Caused by Reduced or Interrupted Shield Gas Flow in Laser Powder Bed Fusion
The Development of a Directed Energy Deposition (DED) Printability Framework for Improving Part Density and Performance in High Strength Martensitic Steels
The Effect of LaserSscan Strategy on Residual Stress of Titanium Alloys Using Laser Foil Printing Additive Manufacturing Processes
The Effect of Near-surface Pores on Fatigue Life of Ti-6Al-4V Components
The Effect of Thermal Conditions on Process Defects in Electron Beam Directed Energy Deposition
The Influence of Heat Treatments on the Microstructure and Tensile Properties of Additively Manufactured Inconel 939
The Use of Laser Preheating for Microstructural Customization of Ti6Al4V Processed Using Diode Point Melting System
The Variation of Mechanical Properties of M300 Maraging Steel Manufactured with Varying Process Parameters in Laser Powder Bed Fusion
The WAAM Number: A Dimensionless Number for Predicting Wire Arc Additive Manufacturing Bead Geometry
Thermal Imaging for Wire Arc Additive Manufacturing Using an Off-the-shelf Color Camera
Thermal Monitoring and Cure Process Modelling of Dual-wavelength VPP Printing
Thermal Simulation of the Material Extrusion Process with Different Print Bed Boundary Conditions
Thermal Stress Prediction in in Laser Powder Bed Fusion
Thermomechanical Modeling and Fabrication of Tungsten Carbide-nickel Geometries Through Laser Powder Bed Fusion
Thin Strand Printing of Silicone Ink with Direct Ink Write Process
Thin Wall Manufacturing in Laser Powder Bed Fusion for Heat Exchanger Applications
Time-optimal Path Planning for Heterogeneous Robots in Swarm Manufacturing
Time-resolved Optical Spectroscopy in Metal Powder Bed Fusion
Toolpath Planning Approach for Parts with Multiple Revolving Features for Wire Arc Additive Manufacturing.
Topology Optimization of Continuous Fiber-reinforced Composites Considering Manufacturing Constraints
Toward Post-superficial Temperature Monitoring During Additive Manufacturing through Data-driven Inpainting
Toward Voxel Level Control for Laser Powder Bed Fusion Additive Manufacturing Process
Towards a FAIR Knowledge Management System for Additive Manufacturing
Towards a Generic Deposition Model in Wire-arc Directed Energy Deposition: A Deep Learning-based Wetted Area Prediction Model
Towards Experimental Process Parameter Development for Ti-6Al-4V TPMS Lattice Structures with Application to Small Scale Dental Implants using Micrographs
Towards Functionally Graded Materials Using Wire-arc Technology
Towards High-throughput Assessment of Printability in Refractory Alloys Systems for Laser-powder Bed Fusion
Towards Large-scale Grain Growth Modeling in Powder Bed Fusion
Towards Large-scale Grain Growth Modeling in Powder Bed Fusion
Towards the Limits in Copper Lattice Production via Fiber Laser Powder Bed Fusion
Transmitting G-Code with Geometry Commands for Extrusion Additive Manufacturing
Two-color Thermal Imaging of WC-Ni Cermet Melt Pools in Laser Powder Bed Fusion
Ultrasonic Non-destructive Characterization of Anisotropic Additively Manufactured Polymers
Uncovering Fundamental Process Deficiencies in Wire-laser Directed Energy Deposition using In-situ High Speed Imaging
Understand Powder Deposition Behaviors of a Novel Electrostatic Powder Spreading Technique Using Particle Dynamics Simulation
Uniaxial Fatigue Behavior and Life Prediction of Additively Manufactured Inconel 718 with Different Grain Morphology
Unveiling Melt Pool Defect Signatures with Interpretable Machine Learning
Unweaving the Macrostructure of the Venus Flower Basket: From Bio-morphism to Biological Insight
Usage of Unconventional Data Sources for Market Intelligence (MI) in the Field of Additive Manufacturing (AM) - Expert Networks, Technology Territories and Trends
Use of a Vibrating Build Platform during Powder-bed Fusion of Metals Using a Laser Beam
Using In-situ Two-color Thermal Imaging to Validate Multi-physics CFD Melt Pool Models for LPBF
Variational Autoencoders for Comprehensive Feature Identification in Fatigue Analysis
Virtual Inspection of Advanced Manufacturing via Digital Twins
Volumetric Additive Manufacturing of Glass
Voxel-free Radon Transform for Improving Surface Quality in Computed Axial Lithography
Wide-field Low-coherence Interferometry for Keyhole Depth Measurements in Laser Powder Bed Fusion
Wire Arc Additive Manufacturing in Steel Foundries
Wire + Arc Additive Manufacturing of Cryogenic Liquid Hydrogen Storage Tank Demonstrator
X-ray Computed Tomographic Study of Density Gradients within Binder Jet Printed H-13 Components
X-Ray Computed Tomography: A Game-Changer for Parameter Control in Additive Manufacturing
You Must Unlearn What You Have Learned: Establishing a DfAM Mindset in the Face of Centuries of Traditional Manufacturing
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