A critical assessment of the Archimedes density method for thin-wall specimens in laser powder bed fusion: Measurement capability, process sensitivity and property correlation

The Archimedes method is a commonly used approach for measuring the density of specimens fabricated with metal additive manufacturing. Most this purpose are cubes 10 mm sides. This work examines appropriateness using estimating thin-wall (0.3–2 thick). significantly higher surface area to volume ratio these specimens, as well their cumbersome size, can introduce measurement challenges not seen standard cubic specimens. assessed thin-walls in three ways: first, Measurement Capability Analysis conducted, quantifying repeatability and reproducibility comparing them those obtained Then, densities sensitivity detecting differences due changes thickness, post-processing conditions (Hot Isostatic Pressing, or HIP) build location. Finally, values correlated mechanical tensile test metrics establish trends R2 values. shown be capable thin wall 0.3 mm, though deviation increase thickness reduces. also sensitive enough detect HIP, lesser extent, from yield interesting insights modulus, ultimate strength elongation, some cases exceeding 0.6. focuses on Inconel 718 laser powder bed fusion process demonstrates that critical tool developing structures.