Nondestructive quantitative characterisation of material phases in metal additive manufacturing using multi-energy synchrotron X-rays microtomography

Xavier, Matheus S.; Yang, Sam; Comte, Christophe; Bab–Hadiashar, Alireza; Wilson, Neil R.; Cole, Ivan

doi:10.1007/s00170-019-04597-y

Cited by 11 publications

(7 citation statements)

References 74 publications

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“…It is a non-destructive observation method and is widely used in the additive manufacturing industry. Defects and their sizes, shapes and locations, which affect the mechanical properties of the final part, can be determined by the micro computerized tomography (microCT) method (Xavier et al , 2020). As the reproducibility of parts by additive manufacturing is not well-known, microCT provides information about each manufactured part’s internal structure.…”

Section: Methodsmentioning

confidence: 99%

Determination of the elastoplastic properties of Ti-6Al-4V alloy manufactured by electron beam melting

Yılmaz,

Gürses,

Şahin

2023

RPJ

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Purpose This study aims to evaluate and assess the elastoplastic properties of Ti-6Al-4V alloy manufactured by Arcam Q20 Plus electron beam melting (EBM) machine by a tensile test campaign and micro computerized tomography (microCT) imaging. Design/methodology/approach ASTM E8 tensile test specimens are designed and manufactured by EBM at an Arcam Q20 Plus machine. Surface quality is improved by machining to discard the effect of surface roughness. After surface machining, hot isostatic pressing (HIP) post-treatment is applied to half of the specimens to remove unsolicited internal defects. ASTM E8 tensile test campaign is carried out simultaneously with digital image correlation to acquire strain data for each sample. Finally, build direction and HIP post-treatment dependencies of elastoplastic properties are analyzed by F-test and t-test statistical analyses methods. Findings Modulus of elasticity presents isotropic behavior for each build direction according to F-test and t-test analysis. Yield and ultimate strengths vary according to build direction and post-treatment. Stiffness and strength properties are superior to conventional Ti-6Al-4V material; however, ductility turns out to be poor for aerospace structures compared to conventional Ti-6Al-4V alloy. In addition, micro CT images show that support structure leads to dense internal defects and pores at applied surfaces. However, HIP post-treatment diminishes those internal defects and pores thoroughly. Originality/value As a novel scientific contribution, this study investigates the effects of three orthogonal build directions on elastoplastic properties, while many studies focus on only two-build directions. Evaluation of Poisson’s ratio is the other originality of this study. Furthermore, another finding through micro CT imaging is that temporary support structures result in intense defects closer to applied surfaces; hence high-stress regions of structures should be avoided to use support structures.

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Section: Methodsmentioning

confidence: 99%

Determination of the elastoplastic properties of Ti-6Al-4V alloy manufactured by electron beam melting

Yılmaz,

Gürses,

Şahin

2023

RPJ

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“…Techniques such as hot isostatic pressing (HIP) or hot forging can help to promote diffusion and bonding between the particles, which can reduce the formation of oxide inclusions. HIP involves subjecting the printed part to high temperatures and pressures to compress and bond the particles, while hot forging involves pressing and shaping the printed part at high temperatures to promote bonding [ 84 ].…”

Section: Challenges In Multimetal Additive Manufacturingmentioning

confidence: 99%

Multimetal Research in Powder Bed Fusion: A Review

et al. 2023

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This article discusses the different forms of powder bed fusion (PBF) techniques, namely laser powder bed fusion (LPBF), electron beam powder bed fusion (EB-PBF) and large-area pulsed laser powder bed fusion (L-APBF). The challenges faced in multimetal additive manufacturing, including material compatibility, porosity, cracks, loss of alloying elements and oxide inclusions, have been extensively discussed. Solutions proposed to overcome these challenges include the optimization of printing parameters, the use of support structures, and post-processing techniques. Future research on metal composites, functionally graded materials, multi-alloy structures and materials with tailored properties are needed to address these challenges and improve the quality and reliability of the final product. The advancement of multimetal additive manufacturing can offer significant benefits for various industries.

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“…For example; optical microscopy methods are restricted to line-of-sight observations and are incompatible with three-dimensional (3D) lattice structures. Similarly, radiographic testing and eddy current inspection can also be challenging for complex structures including patient-specific medical implants; these non-destructive methods are typically used in conjunction with destructive methodologies (Xavier et al , 2020). Of the available NDT technologies, x-ray CT is the most compatible with particle inspection for LB-PBF lattice structures, as it enables evaluation of 3D structures with high-geometric resolution ( Petrick and Simpson, 2016; Senck et al , 2020).…”

Section: Literature Reviewmentioning

confidence: 99%

Algorithmic detection and categorization of partially attached particles in AM structures: a non-destructive method for the certification of lattice implants

Masterton,

Downing,

Lozanovski

et al. 2023

RPJ

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Purpose This paper aims to present a methodology for the detection and categorisation of metal powder particles that are partially attached to additively manufactured lattice structures. It proposes a software algorithm to process micro computed tomography (µCT) image data, thereby providing a systematic and formal basis for the design and certification of powder bed fusion lattice structures, as is required for the certification of medical implants. Design/methodology/approach This paper details the design and development of a software algorithm for the analysis of µCT image data. The algorithm was designed to allow statistical probability of results based on key independent variables. Three data sets with a single unique parameter were input through the algorithm to allow for characterisation and analysis of like data sets. Findings This paper demonstrates the application of the proposed algorithm with three data sets, presenting a detailed visual rendering derived from the input image data, with the partially attached particles highlighted. Histograms for various geometric attributes are output, and a continuous trend between the three different data sets is highlighted based on the single unique parameter. Originality/value This paper presents a novel methodology for non-destructive algorithmic detection and categorisation of partially attached metal powder particles, of which no formal methods exist. This material is available to download as a part of a provided GitHub repository.

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Nondestructive quantitative characterisation of material phases in metal additive manufacturing using multi-energy synchrotron X-rays microtomography

Cited by 11 publications

References 74 publications

Determination of the elastoplastic properties of Ti-6Al-4V alloy manufactured by electron beam melting

Determination of the elastoplastic properties of Ti-6Al-4V alloy manufactured by electron beam melting

Multimetal Research in Powder Bed Fusion: A Review

Algorithmic detection and categorization of partially attached particles in AM structures: a non-destructive method for the certification of lattice implants

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