Local mechanical properties of fine parts produced by additive manufacturing

PROJECT COST:

138 987 $

PRIMA CONTRIBUTION:

30 727 $

PROJECT DETAILS:

Additive manufacturing (AM) by laser powder bed fusion (LPBF) is rapidly advancing in industry, particularly to produce parts with integrated sensors and optimized topologies. Topological optimization often results in thin features, such as walls or rods. During LPBF fabrication, these thin sections experience distinct thermal histories, leading to variations in microstructure and, consequently, mechanical behavior. Therefore, it is essential to accurately measure the mechanical properties of these thin sections in AM parts to ensure reliable and high-quality designs.

To address this, AP&C has partnered with Prof. Brochu’s team to establish a research project focused on the mechanical characterization of thin samples extracted from LPBF-manufactured parts. Mechanical testing protocols developed by Prof. Brochu’s group will be applied to heat exchanger components and mesh structures produced by AP&C. This project will provide accurate tensile and fatigue strength values for these thin sections.

These results are critical for AP&C for several reasons. First, they will enhance the understanding of testing methods and challenges associated with small-scale samples. Second, the data can be used to define reliable design limits, enabling more precise additive manufacturing design tools.

By leveraging this knowledge, AP&C will be better positioned to exploit the full potential of additive manufacturing, producing parts that push the limits of Design for Additive Manufacturing (DfAM). The company will also be able to provide clients with informed guidance on achievable performance with their powders, reinforcing its leadership in AM part production. Since the project is based on AP&C powders, the resulting methodologies and processes are expected to be fully transferable to production.

The project will also provide advanced training opportunities, including the supervision of one doctoral student and one postdoctoral researcher.