Laura Moody¹, Ion Powell¹, Daniel Lewis², Brady G. Butler¹, Ankit Srivastava², Lara Draelos², James D. Paramore¹; ¹United States Army Research Laboratory, ²Texas A&M University

Anisotropy, coarse microstructure, and large porosity are common problems in additive manufacturing (AM) of metals. Non-beam approaches can both simplify the manufacturing processes and produce more reliable microstructures, though verification of improved properties is still necessary. Using sub-scale sized tensile bars to test mechanical properties like strength and ductility enables characterization of AM metals at a variety of locations and orientations within a single component. Additionally, data can be gained from relatively small amounts of material. The goal of this study is to develop and validate sub-scale tensile tests that utilize a truly representative volume element in order to accurately characterize mechanical properties, thereby enabling further development and validation of metal AM processes. The effects of surface finish, size and morphology of the microstructure, and the reliability of measuring small specimen dimensions will be discussed. Additionally, data gained from sub-scale testing of non-beam AM components will be presented.