The surface texture of additively manufactured metallic surfaces made by powder bed methods is affected by a number of factors, including the powder's particle size distribution, the effect of the heat source, the thickness of the printed layers, the angle of the surface relative to the horizontal build bed and the effect of any post processing/finishing. The aim of the research reported here is to understand the way these surfaces should be measured in order to characterise them. In published research to date, the surface texture is generally reported as an Ra value, measured across the lay. The appropriateness of this method for such surfaces is investigated here. A preliminary investigation was carried out on two additive manufacturing processes-selective laser melting (SLM) and electron beam melting (EBM)-focusing on the effect of build angle and post processing. The surfaces were measured using both tactile and optical methods and a range of profile and areal parameters were reported. Test coupons were manufactured at four angles relative to the horizontal plane of the powder bed using both SLM and EBM. The effect of lay-caused by the layered nature of the manufacturing process-was investigated, as was the required sample area for optical measurements. The surfaces were also measured before and after grit blasting.

Industrial X-ray computed tomography (XCT) is seen as a potentially effective tool for industrial inspection of complex parts. In particular, XCT is an attractive solution for the measurement of internal geometries, which are inaccessible by conventional coordinate measuring systems (CMSs). While the technology is available and the benefits are recognized, methods to establish measurement assurance of XCT systems are lacking. More specifically, assessment of measurement uncertainty and the subsequent establishment of measurement traceability is a largely unknown process. This paper is a review of research that contributes to the development of a geometrical calibration procedure for XCT systems. A brief introduction to the geometry of cone-beam tomography systems is given, after which the geometrical influence factors are outlined. Mathematical measurement models play a significant role in understanding how geometrical offsets and misalignments contribute to error in measurements; therefore, the application of mathematical models in simulating geometrical errors is discussed and the corresponding literature is presented. Then, the various methods that have been developed to measure certain geometrical errors are reviewed. The findings from this review are discussed and suggestions are provided for future work towards the development of a comprehensive and practical geometrical calibration procedure.

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Selective laser melting (SLM) of metals produces surface topographies that are challenging to measure. Multiple areal surface topography measurement technologies are available, which allow reconstruction of information rich, three-dimensional digital surface models. However, the capability of such technologies to capture intricate topographic details of SLM parts has not yet been investigated. This work explores the topography of a SLM Ti6Al4V part, as reconstructed from measurements by various optical and non-optical technologies. Discrepancies in the reconstruction of local topographic features are investigated through alignment and quantitative assessment of local differences. ISO 25178-2 areal texture parameters are computed as further comparison indicators.

In this paper, we present methods for determining the measurement noise and residual flatness of areal surface topography-measuring instruments. The methods are compliant with draft international specification standards on areal surface texture. We first introduce the international standards framework and then present current methods based on averaging and subtraction to isolate the measurement noise and residual flatness from the sample surface topography. These methods are relatively difficult to apply and time consuming in practice. An alternative method is presented based on thresholding and filtering techniques. This method is simple to apply in practice. Traceability and measurement uncertainty are discussed.

Methods for determining the amplification coefficient, linearity and squareness of the axes of areal surface topography measuring instruments are presented. The methods are compliant with draft international specification standards on areal surface texture. A method of calibrating the z-axis scale according to the guidelines given in surface profile specification standards, which is applied to areal measurements, is first presented. Then a method of calibrating the scales of the x and y axes using cross grating artefacts, and which is not based on pitch measurement, is introduced. A method for extending the calibrated range of the z-axis scale, which uses multiple overlapped measurements of a step height artefact, is also discussed.

Calibration of the scales of areal surface topography measuring instruments requires testing of the resolution. Several designs of artefact that allow testing of the resolution of such instruments are currently available; however, analysis methods need to be developed to provide comparable results. A novel method for determining the lateral resolution of areal surface topography measuring instruments is presented. The method uses a type ASP (star-shaped) material measure. To demonstrate the validity of the method, the resolution of a phase shifting interferometer was determined based on the ISO definition of the lateral period limit. Using the proposed method, the type ASP material measure, which is often used to judge qualitatively an instrument's resolution, can be used to quantitatively estimate the resolution of instruments using the topography data.