High‐Speed 3D Printing Coupled with Machine Learning to Accelerate Alloy Development for Additive Manufacturing

Advanced Science, vol. 12, pp. e2414880

Abstract

Developing novel alloys for 3D printing of metals is a time- and resource-intensive challenge. High-throughput 3D printing and material characterization protocols are used in this work to rapidly screen a wide range of chemical compositions and processing conditions. In situ, alloying of high-strength steel with pure Al in the targeted range of 0-10 wt.% and flexible adjustment of the volumetric energy input is performed to derive 20 individual alloy combinations. These conditions are characterized using large-area crystallographic analysis combined with chemistry and nanoindentation protocols. The significant influence of Al content and processing conditions on the constitutive material behavior of the metastable base alloy allowed for efficient exploration of the underlying process-structure-properties (PSP) relationships. The extracted PSP relations are discussed based on the dominant physical mechanisms observed in the samples. Furthermore, the microstructure-property relationship based on limited experimental data is supported by an explainable machine-learning approach.

Authors 8

1. Avinash Hariharan corresponding Aachen Steel Institute

   RWTH Aachen University

   Affiliation as printed

   Steel Institute RWTH Aachen University 52072 Aachen Germany

2. Marc Ackermann Aachen Steel Institute

   Salzgitter Group (Germany) · RWTH Aachen University

   Affiliation as printed

   Salzgitter Mannesmann Forschung GmbH 38239 Salzgitter Germany

   Steel Institute RWTH Aachen University 52072 Aachen Germany

3. Stephan Koß Aachen Chair of Digital Additive Production

   RWTH Aachen University

   Affiliation as printed

   Chair of Digital Additive Production RWTH Aachen Aachen Germany

4. Ali Khosravani

   Georgia Institute of Technology

   Affiliation as printed

   Multiscale Technologies llc Atlanta 30308 USA

   Woodruff School of Mechanical Engineering Georgia Institute of Technology Atlanta 30332 USA

5. Johannes Henrich Schleifenbaum Aachen Chair of Digital Additive Production

   RWTH Aachen University

   Affiliation as printed

   Chair of Digital Additive Production RWTH Aachen Aachen Germany

6. Patrick Köhnen
   Affiliation as printed

   GKN Additive 53117 Bonn Germany

7. Surya R. Kalidindi

   Georgia Institute of Technology

   Affiliation as printed

   Woodruff School of Mechanical Engineering Georgia Institute of Technology Atlanta 30332 USA

8. Christian Haase corresponding

   Technische Universität Berlin

   Affiliation as printed

   Center for 3D Technologies Technical University Berlin D‐10623 Berlin Berlin Germany

   Chair Materials for Additive Manufacturing Technical University Berlin D‐10587 Berlin Germany