AM Standards Reference

• • Powder must meet ASTM F3049 characterisation requirements (PSD, morphology, chemistry, flowability)
• • UTS ≥ 930 MPa, YS ≥ 860 MPa, elongation ≥ 10% (as-built, H900 heat treatment)
• • Tensile specimens must be built horizontally (XY) and vertically (Z) to capture anisotropy
• • Chemical composition per ASTM B265 Grade 5 limits
• • Full traceability of powder lot, build parameters, and heat treatment records required

💡 Widely used as the minimum contractual specification for Ti-6Al-4V LPBF parts. HIP + anneal condition often required by aerospace primes; check purchase order carefully. Does not cover ELI grade — use F3001 for medical fracture-critical applications.

• • O ≤ 0.13 wt%, N ≤ 0.05 wt%, Fe ≤ 0.25 wt% (stricter than Grade 5)
• • Biocompatibility testing per ISO 10993 required for implantable applications
• • Fatigue testing often required for fracture-critical implants (ASTM E466/E468)
• • HIP mandatory for most implant applications to eliminate internal porosity

💡 ELI grade commands a price premium (~20–40% over Grade 5 powder). Most orthopaedic implants require this grade. HIP adds significant cost and lead time — factor into design-for-manufacture decisions.

• • PSD: laser diffraction (D10, D50, D90) plus sieve analysis for coarse fraction
• • Morphology: SEM imaging minimum; sphericity measurement recommended
• • Flowability: Hall flowmeter (ASTM B213) or Carney funnel for non-free-flowing powders
• • Apparent density (ASTM B212) and tap density (ASTM B527)
• • Chemical composition: ICP-OES or combustion analysis; trace O and N by inert gas fusion
• • Moisture: Karl Fischer or loss-on-ignition

💡 Guide, not specification — requirements are process- and application-specific. AMS-7xxx specifications call this out as normative for aerospace. Maintain powder traceability records (lot, moisture, PSD on receipt) — auditors will check.

• • UTS ≥ 1240 MPa, YS ≥ 1034 MPa, elongation ≥ 12% (SA+DA condition)
• • SA+DA heat treatment: 980°C/1h + 720°C/8h + 620°C/8h
• • Impact testing required for certain aerospace applications
• • Powder per ASTM F3049; re-use lot management required

💡 SA+DA is the de facto condition for aerospace IN718 LPBF. Verify with customer — some engine applications require additional ageing cycles. Satellite applications sometimes accept stress-relieved condition.

• • UTS ≥ 827 MPa, YS ≥ 414 MPa, elongation ≥ 30% (solution-annealed condition)
• • Solution anneal at 1065–1205°C
• • Powder per ASTM F3049
• • Corrosion testing for marine / chemical applications

💡 IN625 LPBF is used extensively for subsea, aerospace, and chemical processing. Much lower strength floor than IN718 — if you need >900 MPa UTS, specify IN718. Solution anneal typically 1150°C/1h.

• • Test specimens in ≥2 build directions (XY and Z at minimum)
• • Minimum 5 replicates per condition for statistical validity
• • Coupon placement must represent full build envelope (corners, centre, top, bottom)
• • Tensile testing per ASTM E8/E8M
• • Report: build parameters, machine, operator, post-processing details

💡 Required reading before designing any AM material qualification programme. The coupon placement strategy (corners + centre) is routinely under-specified by first-time AM programmes — this guide prevents that mistake.

• • UTS ≥ 485 MPa, YS ≥ 170 MPa, elongation ≥ 40% (solution-annealed condition)
• • As-built UTS typically 600–700 MPa (higher than spec minimum)
• • Pitting corrosion testing for marine/chemical applications
• • Powder per ASTM F3049; O content ≤ 0.03 wt% for as-built

💡 316L is the most widely-used LPBF metal for non-aerospace applications. As-built properties typically exceed spec minimums substantially. Solution anneal reduces strength but improves corrosion resistance and ductility.

• • Co ≥ 58 wt%, Cr 26–30 wt%, Mo 5–7 wt%
• • UTS ≥ 1100 MPa, YS ≥ 900 MPa (solution-annealed condition)
• • Biocompatibility per ISO 10993 required for implants
• • Corrosion testing: ASTM F2129 (electrochemical), ASTM G48 (pitting/crevice)

💡 CoCrMo LPBF is standard for hip and knee arthroplasty components and CADCAM dental frameworks. FDA 510(k) or PMA path depends on classification. EU MDR requires notified body involvement for Class III.

• • Stress relief cycles: material-specific temperatures and hold times
• • Furnace calibration: NADCAP AMS 2750E or equivalent
• • Quench rates for solution anneal must be controlled and documented
• • HIP parameters (temperature, pressure, cycle time) must be qualified
• • Traceability: furnace records, load chart, temperature survey

💡 NADCAP heat treatment accreditation is commonly required by aerospace primes for post-processing under this standard. AMS 2750E furnace class and SAT (System Accuracy Test) records are frequently audited.

• • Process parameter qualification required before production — no assumed equivalence from PBF standards
• • Heat input tracking: laser power, scan speed, and powder feed rate must be recorded for every build
• • Mechanical properties vary with deposition strategy (uni-directional, bi-directional, cross-hatch) — strategy must be documented
• • Microstructure and property gradients in multi-layer deposits must be characterised

💡 DED has more process variability than PBF — qualification is more demanding. This guide provides the framework; material-specific requirements are addressed in supplementary documents or customer purchase specifications.

• • Powder refresh ratio (new vs. recycled) must be documented and controlled
• • Part density: PA12 SLS minimum 0.93 g/cm³ (vs theoretical ~1.01 g/cm³)
• • Tensile properties per ASTM D638 — minimum values in the specification
• • Colour and surface finish uniformity acceptance criteria defined

💡 Key reference for qualifying SLS/MJF suppliers. The refresh ratio (proportion of new powder per build) is the primary process control variable for consistent mechanical properties in polymer PBF.

• • Build direction and specimen orientation per ISO/ASTM 52921 must be reported
• • Post-processing condition: as-built, stress-relieved, HIP, or heat-treated — with cycle details
• • Machine model, laser type, and nominal parameter set must be identified
• • Powder lot traceability if the paper or report is for qualification purposes

💡 Useful when publishing test data or submitting qualification data to a prime. Prevents the common error of reporting tensile properties without stating build orientation, which makes data useless for comparison.

• • NDT method selection must be based on part geometry, material, and critical defect size
• • X-ray CT preferred for internal feature inspection (channels, lattices, enclosed volumes)
• • Surface NDT (FPI/MPI) required after machining, not only after build
• • Calibration standards must be AM-built (not wrought) to account for AM-specific surface texture

💡 Essential reference for qualification of fracture-critical AM aerospace parts. CT scanning is now near-mandatory for first-article inspection of complex internal geometries per this and related guidance.

• • AlSi10Mg composition: Si 9.0–11.0%, Mg 0.20–0.45% per EN AC-43000
• • As-built UTS ≥ 300 MPa, YS ≥ 200 MPa, elongation ≥ 1%
• • T6 condition: UTS ≥ 240 MPa, YS ≥ 160 MPa, elongation ≥ 4%
• • Test specimen orientation (XY and Z) per ISO/ASTM 52921

💡 Use alongside AMS 7047 to cross-reference minimum properties. Note that ASTM F3318 minimum elongation values are conservative — optimised LPBF AlSi10Mg typically achieves 3–7% as-built.

• • Gauge length 4D (round) or 2 in (flat) standard specimens
• • Strain rate 0.005–0.05 min⁻¹ for YS determination
• • Extensometer required for E, YS, and uniform elongation; fracture elongation by manual gauge measurement

• • Load selection determines scale: HV0.1 (micro), HV1, HV10, HV30 (macro)
• • Surface preparation: metallographic polish for microhardness
• • Spacing: 2.5× diagonal from previous indent or edge

• • Specimen: hourglass or straight-gauge; R-ratio, frequency, and environment must be reported
• • Run-out: typically 10⁷ cycles; some AM specs require 10⁸
• • Statistical basis: minimum 6 specimens per stress level; Staircase or S-N regression

• • Minimum specimen thickness B ≥ 2.5(KIC/σ_ys)² to ensure plane strain
• • Pre-crack by fatigue: Kmax/E ≤ 0.6 mm^0.5 at final crack front
• • Validity: K-Q ratio, pop-in, secant offset criteria

• • Precision balance with suspension kit; density liquid (water or ethanol + wetting agent)
• • Report theoretical density source and calculated relative density
• • Method limited to <2% porosity — high-porosity parts need CT or metallographic section

• • Use ISO/ASTM 52900 terminology in all technical documents and standards
• • Process families: Binder Jetting, Directed Energy Deposition, Material Extrusion, Material Jetting, Powder Bed Fusion, Sheet Lamination, Vat Photopolymerisation

💡 All new standards from ASTM F42 and ISO/TC 261 use this terminology. When writing technical documents, avoid legacy names (SLM, DMLM, DMLS) and use the ISO/ASTM 52900 designations.

• • Machine Qualification: regular calibration, acceptance test, beam/laser performance verification
• • Process Qualification: Design of Experiments on key parameters; statistical property verification
• • Procedure Specification: AM Process Specification (AMPS) document required
• • Production Control: witness coupons on every build; end-of-build test
• • Change Management: any process change triggers re-qualification assessment
• • Personnel qualification: operators and engineers require documented training

💡 The de facto framework for aerospace AM process qualification in Europe and increasingly in the US. Many primes (Airbus, MTU, Rolls-Royce) reference this standard in their supplier requirements. NADCAP AC7110/14 for LPBF aligns closely with this standard.

• • Design intent documentation must capture AM-specific decisions (orientation, support strategy, post-processing)
• • Functional requirements must be mapped to process capabilities before design freeze
• • Design review must assess AM-specific failure modes (residual stress, anisotropy, surface roughness)

💡 Useful as a framework document for organisations establishing AM design processes. Not a material or process qualification standard — it is a design methodology guide.

• • Z-axis is the build direction (vertical, parallel to layer stacking)
• • XY plane is parallel to the build plate
• • Test specimen orientation reported as: build direction / specimen axis (e.g. Z/XY means vertical specimen, tensile axis in XY)

💡 Always cite this standard when reporting directional mechanical properties. Many data discrepancies in AM literature are caused by inconsistent orientation reporting.

• • Minimum 5 test builds across the build envelope (corners + centre)
• • Dimensional accuracy: ±0.1 mm for a 50 mm reference artifact
• • Tensile properties must meet process-material standard minimums (e.g. ASTM F2924 for Ti-6Al-4V)
• • Laser power and scan speed calibration verification required before acceptance

💡 Important for organisations receiving a new LPBF machine or qualifying a contract manufacturer. Provides an objective basis for machine acceptance that is independent of the OEM's own testing.

• • Co minimum 58 wt%, Cr 26.0–30.0 wt%, Mo 5.0–7.0 wt%
• • Carbon ≤ 0.14 wt% (high-C) or ≤ 0.08 wt% (low-C)
• • UTS ≥ 900 MPa, YS ≥ 450 MPa, elongation ≥ 20% (wrought; AM parts must meet or exceed)

💡 All CoCrMo implant products must demonstrate conformance to this composition standard. AM parts produced per ASTM F3213 must also meet this composition.

• • Al 5.5–6.75 wt%, V 3.5–4.5 wt%, O ≤ 0.20 wt%
• • Biocompatibility per ISO 10993 series

• • Dimensional accuracy assessed on a standardised artifact (various geometries defined in the standard)
• • Surface roughness per ISO 4288 (Ra, Rz)
• • Mechanical properties via standard ASTM/ISO tensile methods

💡 Partially superseded by the more detailed ISO/ASTM 52900 series but still cited in some European qualification schemes. Check whether your customer specification references 17296-3 or 52900-series.

• • Cut-off λc: select based on expected Ra (0.08, 0.25, 0.8, 2.5, 8 mm)
• • Measurement length: 5× cut-off minimum
• • Report filter type (Gaussian), cut-off, and measurement direction

• • Machine qualification: laser power, scan speed, spot size, atmosphere O₂ monitoring
• • AM Process Specification (AMPS) document required for every material-machine combination
• • Witness coupon requirements: location and testing frequency defined
• • Powder lot control: certification, storage, re-use limits
• • Build record: complete parameter set, atmosphere log, environmental conditions

💡 Referenced by most US aerospace primes (Boeing, Lockheed, GE, Pratt & Whitney) in their AM supplier requirements. NADCAP accreditation to AC7110/14 demonstrates compliance. AMS7000 + NADCAP is the US aerospace AM quality baseline.

• • O ≤ 0.13 wt% (ELI grade)
• • Annealing cycle: 704–843°C for 2h minimum
• • Hot Isostatic Pressing: 899–949°C / 100 MPa / 2h minimum
• • UTS ≥ 896 MPa, YS ≥ 827 MPa (annealed + HIP condition)
• • Fluorescent Penetrant Inspection (FPI) to AMS 2647
• • Ultrasonic testing for thick sections

💡 Used on primary aerospace structures and engine components. HIP is effectively mandatory — porosity limits at fracture-critical levels cannot be met without it. FPI every build, not just qualification builds.

• • UTS ≥ 930 MPa, YS ≥ 862 MPa (stress-relieved)
• • Stress relief: 670–705°C / 1–4h
• • Powder per ASTM F3049 and AMS 4928 composition
• • CMM dimensional verification of first article

• • HIP: 899–949°C / 100 MPa / 2h minimum (ASTM F3301)
• • Anneal: 704–843°C / 2h minimum after HIP
• • UTS ≥ 896 MPa, YS ≥ 827 MPa (HIP+annealed)
• • FPI after HIP to detect surface-breaking indications

• • Grade 23 (ELI): O ≤ 0.13 wt%
• • HIP + solution anneal + age or anneal as specified
• • UTS ≥ 896 MPa, YS ≥ 827 MPa, elongation ≥ 10%, fracture toughness Kq ≥ 55 MPa√m
• • Full volumetric inspection: CT scanning strongly recommended for fracture-critical parts

💡 The most comprehensive Ti-6Al-4V ELI LPBF specification. Used for primary flight structures, rotating components, and fracture-critical implant structures. X-ray CT is expected, not just FPI.

• • SA: 980°C / 1h / rapid cool; DA: 720°C / 8h / furnace cool to 620°C / 8h / AC
• • UTS ≥ 1240 MPa, YS ≥ 1034 MPa, elongation ≥ 12%, reduction in area ≥ 15%
• • Stress rupture testing at 649°C / 690 MPa for turbine applications
• • FPI, dimensional, and where specified, CT scan

💡 SA+DA is mandatory — there is no shortcut for IN718 aerospace turbomachinery. Alloy segregation during AM can affect δ-phase precipitation; validate with metallographic cross-section before first production build.

• • Valid NADCAP accreditation for LPBF must be renewed every 12–18 months
• • Machine: laser power, scan speed, atmosphere monitoring, preheat — all must be controlled and recorded
• • Process: AMPS (AM Process Specification) document, qualified parameter set
• • Powder: traceability from melt, incoming inspection, storage, re-use tracking
• • Witness coupons: one set per build, tested per material spec
• • Personnel: operator training and qualification records
• • Heat treatment: NADCAP heat treatment accreditation typically required (AMS 2750E)

💡 Getting NADCAP for LPBF takes 9–18 months for a new facility. The audit is rigorous — machine qualification data, SPC records, and powder traceability must all be in place before the audit. Merit or Silver/Gold status reduces audit frequency.