ASTM F3554-22

This international standard was developed in accordance with internationally recognized principles on standardization established in the Decision on Principles for the
Development of International Standards, Guides and Recommendations issued by the World Trade Organization Technical Barriers to Trade (TBT) Committee.
Designation:F3554 −22
Standard Specification for
Additive Manufacturing – Finished Part Properties – Grade
4340 (UNS G43400) via Laser Beam Powder Bed Fusion for
Transportation Applications
This standard is issued under the fixed designation F3554; the number immediately following the designation indicates the year of
original adoption or, in the case of revision, the year of last revision. A number in parentheses indicates the year of last reapproval. A
superscript epsilon (´) indicates an editorial change since the last revision or reapproval.
1. Scope Development of International Standards, Guides and Recom-
mendations issued by the World Trade Organization Technical
1.1 This specification covers additive manufacturing of
Barriers to Trade (TBT) Committee.
parts manufactured via laser beam powder bed fusion (PBF-
LB) processing of Grade 4340 (UNS G43400) used in trans-
2. Referenced Documents
portationapplications,includingautomotiveapplications.Parts
2.1 ASTM Standards:
made using this processing method require heat treatment to
B822 Test Method for Particle Size Distribution of Metal
achieve maximum strength and are typically used in applica-
Powders and Related Compounds by Light Scattering
tions that require mechanical properties similar to wrought
D3951 Practice for Commercial Packaging
Grade 4340 (UNS G43400) products. Products built to this
E3 Guide for Preparation of Metallographic Specimens
specification may require additional post-processing in the
E8/E8M Test Methods for Tension Testing of Metallic Ma-
form of machining, polishing etc. to meet necessary surface
terials
finish and dimensional tolerances.
E10 Test Method for Brinell Hardness of Metallic Materials
1.2 This specification describes the required facility,
E29 Practice for Using Significant Digits in Test Data to
training, equipment, and processing requirements necessary to
Determine Conformance with Specifications
support the production of parts with properties and associated
E407 Practice for Microetching Metals and Alloys
quality metrics outlined in a part classification structure.
E112 Test Methods for Determining Average Grain Size
E1019 Test Methods for Determination of Carbon, Sulfur,
1.3 This specification is intended for the use of purchasers
Nitrogen, and Oxygen in Steel, Iron, Nickel, and Cobalt
or producers, or both, of PBF-LB Grade 4340 (UNS G43400)
parts for defining the requirements based on classification Alloys by Various Combustion and Inert Gas Fusion
Techniques
methodology. These requirements shall be agreed upon by the
part supplier and purchaser. E1245 Practice for Determining the Inclusion or Second-
Phase Constituent Content of Metals byAutomatic Image
1.4 Users are advised to use this specification as a basis for
Analysis
obtainingpartsthatwillmeettheminimumacceptancerequire-
E1417 Practice for Liquid Penetrant Testing
ments established and revised by consensus of committee
E1479 Practice for Describing and Specifying Inductively
members.
Coupled Plasma Atomic Emission Spectrometers
1.5 User requirements considered more stringent may be
E1742 Practice for Radiographic Examination
met by additional requirements in the purchase order.
E2234 Practice for Sampling a Stream of Product by Attri-
butes Indexed by AQL
1.6 The values stated in SI units are to be regarded as
E2594 Test Method forAnalysis of NickelAlloys by Induc-
standard. The values given in parentheses after SI units are
tively Coupled Plasma Atomic Emission Spectrometry
provided for information only and are not considered standard.
(Performance-Based)
1.7 This international standard was developed in accor-
E2762 Practice for Sampling a Stream of Product by Vari-
dance with internationally recognized principles on standard-
ables Indexed by AQL
ization established in the Decision on Principles for the
F2971 Practice for Reporting Data for Test Specimens Pre-
pared by Additive Manufacturing
This specification is under the jurisdiction of ASTM Committee F42 on
Additive Manufacturing Technologies and is the direct responsibility of Subcom- For referenced ASTM standards, visit the ASTM website, www.astm.org, or
mittee F42.07 on Applications. contact ASTM Customer Service at service@astm.org. For Annual Book of ASTM
Current edition approved Oct. 1, 2022. Published November 2022. DOI: Standards volume information, refer to the standard’s Document Summary page on
10.1520/F3554-22. the ASTM website.
Copyright © ASTM International, 100 Barr Harbor Drive, PO Box C700, West Conshohocken, PA 19428-2959. United States
F3554−22
F3122 Guide for Evaluating Mechanical Properties of Metal 2.7 ANSI/ASNT:
Materials Made via Additive Manufacturing Processes CP189 Standard for Qualification and Certification of Non-
destructive Testing Personnel
F3301 AdditiveManufacturing–PostProcessingMethods–
Standard Specification forThermal Post-Processing Metal
3. Terminology
Parts Made Via Powder Bed Fusion
3.1 Definitions of Terms:
2.2 ISO/ASTM Standards:
3.1.1 Terminology relating to additive manufacturing in
52900 Additive manufacturing — General principles —
Terminology ISO/ASTM 52900 shall apply.
Fundamentals and vocabulary
3.1.2 Part positioning and orientation related to coordinate
52901 Guide for Additive Manufacturing – General Prin-
systems in ISO/ASTM 52921 shall apply.
ciples – Requirements for Purchased AM Parts
52904 AdditiveManufacturing–ProcessCharacteristicsand
4. Classification
Performance: Practice for Metal Powder Bed Fusion
4.1 All parts made to this specification shall be given a
Process to Meet Critical Applications
classification A, B, C, D, according to the annex.
52921 Terminology for Additive Manufacturing-Coordinate
Systems and Test Methodologies
5. Condition
52930 Additive manufacturing — Qualification principles
5.1 All Conditions shall meet the requirements in each
— Installation, operation, and performance (IQ/OQ/PQ)
section of this standard and conform to Specification F3301.
of PBFLB equipment
5.1.1 Condition SR, parts shall be stress relieved.
52941 Additive Manufacturing — System performance and
5.1.2 Condition Q/T, parts shall be quenched and tempered.
reliability —AcceptanceTests for laser metal powder bed
5.1.3 Condition HIP, parts shall be processed by hot iso-
fusion machines for metallic materials for aerospace
static pressing.
application
52942 Additive Manufacturing — Qualification principles 5.2 The purchaser may specify multiple conditions on the
purchase order such as Condition SR/HIP.
— Qualifying machine operators of metal laser powder
5.2.1 Class A parts shall be delivered in condition HIP and
bed fusion machines and equipment used in aerospace
Q/T.
applications
5.2.2 Class B parts shall be delivered in condition Q/T.
2.3 ISO Standards:
5.2.3 Class C parts shall be delivered in condition SR.
ISO 9001 Quality management system — Requirements
5.2.4 Class D parts shall be delivered in condition as agreed
ISO 9044 Industrial woven wire cloth — Technical require-
upon between supplier and purchaser.
ments and testing
ISO 9712 Non-destructive testing — Qualification and cer-
6. Ordering Information
tification of NDT personnel
6.1 Parts shall be ordered in accordance with ISO/ASTM
ISO 16949 Quality management systems — Particular re-
52901 and include the specified condition(s) and classification
quirements for the application of ISO 9001:2008 for
in accordance with this specification.
automotive production and relevant service part organiza-
6.2 Supplementary requirements shall be stated on the
tions
purchase order.
2.4 SAE Standards:
AS 9100 Quality Management Systems – Requirements for
7. Manufacturing Plan
Aviation, Space and Defense Organizations
7.1 All classification of parts manufactured to this specifi-
AMS 2175 Castings, Classification, and Inspection of
cation shall have a manufacturing plan in accordance with
2.5 ASME Standards:
ISO/ASTM 52904.
ASME B46.1 Surface Texture
8. Feedstock and Powder Batches
2.6 National Aerospace Standards:
NAS410 National Aerospace Standard Certification & 8.1 Classifications A, B, C of parts manufactured to this
Qualification of Non-destructive Test Personnel specification shall use pre-alloyed powder and control powder
batches in accordance with ISO/ASTM 52904.
8.1.1 The part manufacturer shall flow-down powder speci-
fications to their powder vendor and have receiving procedures
Available from International Organization for Standardization (ISO), ISO
that ensure the powder meets the requirements in ISO/ASTM
Central Secretariat, Chemin de Blandonnet 8, CP 401, 1214 Vernier, Geneva,
Switzerland, https://www.iso.org.
52904.
Available from SAE International (SAE), 400 Commonwealth Dr.,Warrendale,
PA 15096, http://www.sae.org.
Available from American Society of Mechanical Engineers (ASME), ASME
International Headquarters, Two Park Ave., New York, NY 10016-5990, http:// Available fromAmerican National Standards Institute (ANSI), 25 W. 43rd St.,
www.asme.org. 4th Floor, New York, NY 10036, http://www.ansi.org and American Society for
Available from Aerospace Industries Association (AIA), 1000 Wilson Blvd., Nondestructive Testing (ASNT), P.O. Box 28518, 1711 Arlingate Ln., Columbus,
Suite 1700, Arlington, VA 22209, http://www.aia-aerospace.org. OH 43228-0518, http://www.asnt.org.
F3554−22
8.1.2 Virgin and used powder may be mixed to produce 11.2 All classifications of parts manufactured to this speci-
parts for all classifications. Used powder shall meet the fication shall meet the requirements of ISO/ASTM 52904 for:
requirements of ISO/ASTM 52904.
11.2.1 Control of machine operating system software.
8.1.3 For Class A part production, the process for sieving
11.2.2 Digital data configuration control.
usedfeedstockshallmaintainthepowderspecificationin8.1.1.
11.2.3 External (to the PBF-LB process) environment
8.1.4 For ClassApart production, the supplier shall provide
control.
objective evidence that changing the alloy type in the PBF-LB
11.3 Permissibleparameterorprocesschangesandextentof
machine does not cause part contamination.
external intervention during the build cycle shall be identified
in the manufacturing plan.
9. Machine Qualification (Class A, B, C)
11.3.1 This requires a new first article inspection (FAI) for
9.1 Allmachinesproducingpartsshallbewithinacceptance
Class A and B.
limits defined in ISO/ASTM 52941.
11.3.2 Allprocesschangesshallbemonitoredandrecorded.
9.2 Keyprocessvariablesshallbedeterminedinaccordance
When agreed to by the purchaser, minor changes to the
with ISO/ASTM 52930.
manufacturing plan may be made without re-qualification, for
9.3 When the process can meet the microstructure density example, change of operation sequences.
requirements in Section 13, the process shall be fixed with no
11.4 Post processing operations may be used to achieve the
additional changes to key process variables under process
desired shape, size, surface finish or other part properties.
controls in ISO/ASTM 52904.
9.4 Initial machine and material qualification shall consist
12. Chemical Composition Evaluation
of three builds each with a minimum of 16 tension test
12.1 As built chemical composition of parts shall conform
specimens and 4 density test specimens. Test specimen orien-
totherequirementsspecifiedinTable1.Methodsandpractices
tation shall be 12 in the Z direction, 2 in the X direction, 2 in
relating to as built chemical analysis required by this specifi-
the Y direction located within the XY build envelope intended
cationshallbeinaccordancewithPracticeE1479.TestMethod
for part production.
E1019 shall be used to measure carbon, nitrogen, and sulfur.
9.4.1 Tension test specimens shall meet the requirements in
RemainingelementsshallbemeasuredinaccordancewithTest
Section 14 after machining to Test Method E8/E8M dimen-
Method E2594. Other analytical methods may be used if
sions
agreed upon by the part supplier and purchaser.
9.4.2 Density test specimens shall meet the requirements in
12.1.1 Analysis for elements not listed in Table 1 is not
Section 13 when processed with only hatch scanning.
required to certify compliance with this specification.
9.4.3 Chemical composition shall meet the requirements in
Section 12.
12.2 Chemical check (product) analysis limits shall be as
shown in Table 2. Chemical check analysis tolerances do not
9.5 Uponsuccessfulcompletionof9.4,themachineshallbe
broaden the requirements in Table 1 for the powder or part
considered qualified. Changes to the key process variables
supplier but cover variations between laboratories in the
require re-qualification in accordance with Section 9.
measurement of chemical content. The part supplier shall not
9.6 Class D parts are exempt from machine qualification.
certify parts to this specification if the part chemistry is outside
the requirements specified in Table 1.
10. Personnel Training Requirements (Class A, B, C)
12.3 The chemical composition requirements in this speci-
10.1 Build programmers and machine operators as defined
fication for as built product conforms to Grade 4340 (UNS
in ISO/ASTM 52904 shall be trained in accordance with
G43400)exceptsulfurandphosphorusarelimitedto0.01mass
ISO/ASTM 52942 and ISO/ASTM 52904.
fraction % to prevent embrittlement and cracking.
11. Process (Class A, B, C)
12.4 Limits for elements not specified in Table 1 and Table
11.1 Process shall be agreed upon by the part supplier and 2 for the material ordered may be established by agreement
purchaser. between the part supplier and purchaser.
A,B,C
TABLE 1 Chemical Composition Requirements (mass fraction %)
Other Other
Phosphorus, Sulfur,
Material Carbon Manganese Silicon Chromium Nickel Molybdenum Elements, Elements,
max max
B B
max each max total
As built 0.38 – 0.43 0.65 – 0.90 0.15 – 0.350 0.01 0.01 0.70 – 0.90 1.65 – 2.0 0.20 – 0.30 0.10 0.40
Material
A
The percentage of iron content by difference is not required to be determined or certified.
B
Other elements need not be reported unless the concentration level is greater than 0.1 % each, or 0.4 % total. Intentional elemental additions other than those specified
in Table 1 are not permitted. All commercial metals contain small amounts of elements other than those which are specified. It is neither practical nor necessary to specify
limits for unspecified elements, whether residual elements or trace elements that can be present. The producer is permitted to analyze for unspecified elements and is
permitted to report such analyses. The presence of an unspecified element and the reporting of an analysis for that element shall not be a basis for rejection.
C
Phosphorus and sulfur concentrations numbers are reduced from Grade 4340 (UNS G43400).
F3554−22
TABLE 2 Check Analysis Limits (Tolerances) (mass fraction %)
14.1.2 For Class C parts, test specimens, in accordance with
Element Permissible Variation in Check 14.1.1, may be produced before and after a production run
Analysis
instead of per build cycle.
Carbon ±0.02
14.1.3 Class D parts do not require mechanical testing. See
Manganese ±0.03
Table 3.
Silicon ±0.05
Phosphorus ±0.005
14.2 Build platform coordinates and orientation for test
Sulfur ±0.005
specimens shall be recorded in accordance with ISO/ASTM
Chromium ±0.03
Nickel ±0.03
52921.
Molybdenum ±0.03
Other Elements, each ±0.001 14.3 Tensiontestspecimensshallbepreparedinaccordance
with Test Method E8/E8M, in the condition of the delivered
part.
NOTE 1—Guide F3122 provides guidance on evaluating mechanical
12.5 Results of supplementary element analysis shall be
properties.
reported on the certification.
14.4 Specimens used for tension testing shall be machined
13. Microstructure of PBF-LB Grade 4340 (UNS
from bulk deposition, machined from bars, or taken from near
G43400)
net shape specimens and built in the weakest orientation or
highest variability orientation, or both, as determined during
13.1 ForClassAparts,densityintheasbuiltconditionshall
the machine and material qualification.
be ≥99.7 % with an even distribution of pores as measured in
NOTE2—Mechanicalpropertiesofthetestspecimensmayvarybecause
accordance with Practice E1245 with a microscopic field of
of factors such as t
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