Diagnosis of fatigue cracks in structural elements manufactured by additive manufacturing

Abstract

Recently, the production of metal structural elements using additive processes is gaining popularity. They allow the production of an element of any geometry and structure, while reducing the mass of the produced part. Unfortunately, the AM technology causes structural elements to be burdened with numerous defects in the form of porosity, unmelted powder, weak interlayer bonds or residual stresses, etc. These defects translate into the possibility of an early, uncontrolled fatigue crack. For this reason, it is important to find ways to quickly detect damage caused by random variable loads. The work presents methods of diagnosing cracks and fatigue damage in structural elements produced using 3D printing. The division of research methods allowing for the detection of defects in structural elements and the characteristics of the most popular methods, taking into account their advantages and limitations, were presented. Methods appropriate for a given type of material, test conditions and damages are indicated. The most important methods of diagnosing defects in printed elements include: penetrating, ultrasonic, radiographic, eddy current and thermal imaging methods.