Summary of NDE of additive manufacturing efforts in NASA

Waller, Jess; Saulsberry, Regor; Parker, Bradford H.; Hodges, Kenneth; Burke, Eric; Taminger, Karen M. B.

doi:10.1063/1.4914594

Cited by 34 publications

(23 citation statements)

References 2 publications

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“…7 One of the key barriers is that existing NDE methods are not optimized for AM processes and materials, although it can be used as one of the validation/qualification tools. Figure 13 is provided to demonstrate how micro-computerized tomography (lCT) can be used in as-deposited (or postprocessed) materials to detect various defects.…”

Section: Non-destructive Inspection/ Evaluation (Lct) Of Defect Distrmentioning

confidence: 99%

“…Various roadmap efforts have been conducted for AM 4,5 as well as updates regarding the status of research needs for qualification and certification. 6,7 The recent review of the metal AM process by Frazier 8 highlights the drastic variability in the various stages in process that produces multiple challenges for the development of qualification standards. Other recent reviews 9,10 dealing with qualification/certification highlight additional needs.…”

Section: Introductionmentioning

confidence: 99%

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Overview of Materials Qualification Needs for Metal Additive Manufacturing

Seifi

Salem

Beuth

et al. 2016

JOM

489

183

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This overview highlights some of the key aspects regarding materials qualification needs across the additive manufacturing (AM) spectrum. AM technology has experienced considerable publicity and growth in the past few years with many successful insertions for non-mission-critical applications. However, to meet the full potential that AM has to offer, especially for flightcritical components (e.g., rotating parts, fracture-critical parts, etc.), qualification and certification efforts are necessary. While development of qualification standards will address some of these needs, this overview outlines some of the other key areas that will need to be considered in the qualification path, including various process-, microstructure-, and fracture-modeling activities in addition to integrating these with lifing activities targeting specific components. Ongoing work in the Advanced Manufacturing and Mechanical Reliability Center at Case Western Reserve University is focusing on fracture and fatigue testing to rapidly assess critical mechanical properties of some titanium alloys before and after post-processing, in addition to conducting nondestructive testing/evaluation using micro-computerized tomography at General Electric. Process mapping studies are being conducted at Carnegie Mellon University while large area microstructure characterization and informatics (EBSD and BSE) analyses are being conducted at Materials Resources LLC to enable future integration of these efforts via an Integrated Computational Materials Engineering approach to AM. Possible future pathways for materials qualification are provided.

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Section: Non-destructive Inspection/ Evaluation (Lct) Of Defect Distrmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

Overview of Materials Qualification Needs for Metal Additive Manufacturing

Seifi

Salem

Beuth

et al. 2016

JOM

489

183

View full text Add to dashboard Cite

show abstract

“…Non-destructive evaluation (NDE) is one type of test that is often associated with AM, as more traditional inspection methods can be destructive and therefore expensive [31]. NDE methods include remote visual inspection, industrial CT scanning, dye penetrant inspection, magnetic-particle inspection, ultrasonic inspection, eddy-current inspection, acoustic emission inspection, thermographic inspection, and stereomicroscope inspection methods.…”

Section: Key Attributes For Producibility Repeatability and Reprodumentioning

confidence: 99%

Toward a Digital Thread and Data Package for Metals-Additive Manufacturing

Kim

Witherell

et al. 2017

Smart and Sustainable Manufacturing Systems

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Additive manufacturing (AM) has been envisioned by many as a driving factor of the next industrial revolution. Potential benefits of AM adoption include the production of low-volume, customized, complicated parts/products, supply chain efficiencies, shortened time-to-market, and environmental sustainability. Work remains, however, for AM to reach the status of a full production-ready technology. Whereas the ability to create unique 3D geometries has been generally proven, production challenges remain, including lack of (1) data manageability through information management systems, (2) traceability to promote product producibility, process repeatability, and part-to-part reproducibility, and (3) accountability through mature certification and qualification methodologies. To address these challenges in part, this paper discusses the building of data models to support the development of validation and conformance methodologies in AM. We present an AM information map that leverages informatics to facilitate part producibility, process repeatability, and part-to-part reproducibility in an AM process. We present three separate case studies to demonstrate the importance of establishing baseline data structures and part provenance through an AM digital thread.

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“…However, the system can only detect near-surface defects, and the cost of the equipment is quite high [10]. The national aeronautics and space administration (NASA) research center introduced the ultrasonic phase array used for testing embedded voids or weak deposition layers of 2219 aluminum electron-beam freeform fabrication parts [11]. An ultrasonic array is a multi-channel ultrasonic technology that has the characteristics of higher detection accuracy and faster detection speed, usually used in NDT of complex structures and special materials in different fields such as aerospace, nuclear power, petroleum, and other field equipment [12,13,14].…”

Section: Introductionmentioning

confidence: 99%

Application of Ultrasonic Array Method for the Inspection of TC18 Addictive Manufacturing Titanium Alloy

Zhou

2019

Sensors

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Ultrasonic arrays have been investigated for inspecting the quality of special materials. Unfortunately, non-destructive testing and evaluation (NDT&E) of internal defects in additive manufacturing (AM) materials are difficult due to the anisotropy and the coarse grain. To solve the problem, this paper brings forward research on the inspection of TC18 AM titanium alloy products using an ultrasonic array. Firstly, a three-dimensional acoustic field distribution of different ultrasonic array transducers is established to design an optimal detection solution for an AM titanium alloy. Then, a total focusing method (TFM) for the ultrasonic annular array transducer is proposed and its imaging method is analyzed. Besides, the relation between ultrasonic group velocities in a TC18 AM specimen with different propagating angles is measured using the full matrix capture (FMC) method. Based on the measurements, the anisotropy of the AM titanium alloy is discussed and the TFM algorithm of annular array is optimized as well. Finally, C-scan experiments are conducted on the specimen with a height of 55 mm using the linear ultrasonic array transducer of the conventional focusing method and the TFM of annular array transducer, respectively. The results show that the TFM of annular array has higher accuracy in quantifying the defects of flat bottom holes and transverse holes with a diameter of 0.8 mm. In addition, the detection results of different forming directions are analyzed and the 3D imaging of defects in the specimen is realized based on FMC data. The TFM of annular array is an innovative ultrasonic testing technology with high resolution for AM titanium alloy products.

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Summary of NDE of additive manufacturing efforts in NASA

Cited by 34 publications

References 2 publications

Overview of Materials Qualification Needs for Metal Additive Manufacturing

Overview of Materials Qualification Needs for Metal Additive Manufacturing

Toward a Digital Thread and Data Package for Metals-Additive Manufacturing

Application of Ultrasonic Array Method for the Inspection of TC18 Addictive Manufacturing Titanium Alloy

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