NDT Challenges and Solutions for Metal Additive Manufactured (AM) Parts & Structures

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Eleanore Goodman
5 years ago
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1 NDT Challenges and Solutions for Metal Additive Manufactured (AM) Parts & Structures Space Tech Expo Bremen, Germany, October

2 Everything starts with the Process Map 2

3 Process Chain - AM 1 3D-Model, Drawing and Bill of Materials 7 Sand Blasting 2 Job Preparation in Software 8 Hot Isostatic Pressing 3 4 3D-Printing (SLM) Stress Relief Heat Treatment 9 10 Non destructive testing (µct) Machining / Polishing 5 EDM Wire Cutting 11 Pickling / Penetrant Testing 6 Support Removal 12 Final Inspection / Marking / Packing Source: Airbus/BDLI 3

Treatment EDM Wire Cutting 9 10 11 Non destructive testing (µct) Machining / Polishing

4 Process Chain AM Quality/NDT 1 3D-Model, Drawing and Bill of Materials 7 Sand Blasting 2 Job Preparation in Software 8 Hot Isostatic Pressing D-Printing (SLM) Stress Relief Heat Treatment EDM Wire Cutting Non destructive testing (µct) Machining / Polishing Pickling / Penetrant Testing 6 Support Removal 12 Final Inspection / Marking / Packing Source: Airbus/BDLI 4

5 NDT Simulation 1 3D-Model, Drawing and Bill of Materials 5

Analysis of CAD models and components for synthetic data Definition of

6 RT / CT-Simulation Need for RT/CT-Simulation solution to analyze the inspectability during the design process. Analysis of CAD models and components for synthetic data Definition of CT-simulation environment and parameters CAD designed AM components and results, inspectability modeling & CT-simulation flaw data 6

7 Powder Quality 3 3D-Printing (SLM) 7

8 Powder Quality Powder Quality is key for good part properties! Source: Airbus Spec: AIPS Additive Manufacturing Powder Bed Fusion 8

Powder Quality analysis & cleaning Powder Quality check on-the-fly Automated and fast determination of powder properties (form, humidity, contamination, etc.

9 Powder Quality analysis & cleaning Powder Quality check on-the-fly Automated and fast determination of powder properties (form, humidity, contamination, etc.) Supervision of the powder quality during the printing process to enable the interruption of the printing in case of contamination Automated cleaning in case of contamination Quality check and cleaning of the powder in case of re-usage of powder to save costs 9

10 Non-Destructive-Testing (NDT) 9 Non destructive testing (µct) 10

11 Defect Catalogue Defect catalogues for LB and EB Powder Bed Fusion Defect type Location Description Visual FPI X-Ray CT Scan External defects / distortion External Surface porosity, roughness, texture External Internal porosity Internal Inclusion (foreign material) Internal / External (external) (external) Lack of fusion (unmolten layers) Internal/externa l (external) (external) No (1) No (1) (1) :To capture the Lack of fusion defect is Hot Isostatic Pressure (HIP) required which eliminates this internal failure with the view on Ti6Al4V. To avoid HIP we need to guaranty that no internal lack of fusion is there. A solution could be a detailed process monitoring (on-line process monitoring). Source: Airbus 11

12 Acceptance Levels Source: Airbus Spec: AIPS Additive Manufacturing Powder Bed Fusion 12

13 Application of NDT Source: Airbus Spec: AIPS Additive Manufacturing Powder Bed Fusion 13

14 Defects to be detected Failure Requirements stated in the AIMS and the AIPS: 200 µm 3,2 µm Source: Airbus Spec: AIPS Additive Manufacturing Powder Bed Fusion 100 µm!! Great challenge for surface treatment 14

15 Internal Defects Digital X-Ray 9 Non destructive testing (µct) 15

16 X-Ray Non-Film / Digital X-Ray Source: GE Inspection Technologies Industrial Radiography 16

17 Internal Defects Computer Tomography (CT) 9 Non destructive testing (µct) 17

18 Laminography Computed Tomography Different CT-Methods Conventional-CT Helix-CT Translational Laminography Rotational-CT 18

19 Overview of sample sizes Micro Scale ~ 20 mm Macro Scale Macro+ Scale > 5000 mm 19

20 One CT-Measurement and three Analyses 260 mm Porosity Wall-Thickness Geometric Deviation 20

21 AM-Part Inspection Pore/Defect analysis 2D evaluation 21

22 AM-Part Inspection Crack analysis 22

23 Powder Residues Foreign Particle Inspection 23

24 Geometrical Analysis Online/Offline assessment: Thickness Shape Dimensions Reverse Engineering 24

Used CT-Systems in Testia Testia CT Micro Focus (Ottobrunn) TESTIA CT

Focus CT / Laminography* Macro-CT* Mini Focus Robotic RT (Dragonfly)* 225

power 150 W 350 W 150 W 1,5 kw 90 kw (pulsed)/1,5 kw --- High Energy CT*

object weight PerkinElmer 20x20 cm, 200 µm Varian 4343 PerkinElmer 40x40

μm Row Detector 4000 cm 400 μm 10 kg < 50 kg 50 kg 150 kg 100 kg 10 000 kg

size High resolution CT Small, medium and large sized components up to Ø

25 Used CT-Systems in Testia Testia CT Micro Focus (Ottobrunn) TESTIA CT System (Ottobrunn) X-Ray Source 225 kv X-RAY WorX XWT-300- CT 300 kv Micro Focus CT / Laminography* Macro-CT* Mini Focus Robotic RT (Dragonfly)* 225 kv 600 kv 120 kv/225 kv 9 MeV Max. power 150 W 350 W 150 W 1,5 kw 90 kw (pulsed)/1,5 kw --- High Energy CT* Detector Max. object weight PerkinElmer 20x20 cm, 200 µm Varian 4343 PerkinElmer 40x40 cm, 200 μm PerkinElmer 40x40 cm, 200 μm Fraunhofer XEye 40x20 cm, μm Row Detector 4000 cm 400 μm 10 kg < 50 kg 50 kg 150 kg 100 kg kg Max. Resolution ~ 3 µm ~ 3 µm ~ 5 µm ~ 110 µm ~ 150 µm ~ 200 μm Object size High resolution CT Small, medium and large sized components up to Ø 500 mm, h 1000 mm (with range extension) Standard CT High density objects (RT/CT) High-Speed image acquiring (RT) Large and high density objects (RT/CT) *In cooperation with Fraunhofer EZRT 25

26 External Defects Penetrant Testing (PT) 9 Non destructive testing (µct) 26

27 Penetrant Testing (PT) Standard method for castings Currently mandatory acc. to Airbus requirements Surface roughness biggest challenge Electro polished AM-specimen AM-specimen before electro polishing 27

28 Automisation 9 Non destructive testing (µct) 28

29 Fully automated systems possible PT Systems X-Ray Turn-Key Solutions CT Turn-Key Solutions 29

30 Testing Mechanical, Physical, Chemical, etc 30

31 Testing Beside NDT, Destructive Testing (DT) is necessary Typical tests: - Tensile tests - Compression tests - Shear tests - Metallography - Hardness tests - Fatigue tests - Fracture toughness tests - Mechanical samples manufactured during printing process 31

32 Online Monitoring End-to-End 32

33 Merge NDT and AM Process data Integral view of data Reducing duplication of work & cost Information about correlation between connected data Better check for origin of effect and influence to data Optimization of process steps by using connected database NDT Data NDT Department generates test data of finished parts. Production Data Sensor Systems monitor production quality and record every defect. Connected Data Analytics Chain Apps collect and analyze data of production and may relate it to NDT data. *In cooperation with InFactory 33

34 Other relevant topics 34

fusion quality during process Calibrated

35 Live NDT monitoring of printing process Check Laser Power Check of Accuracy of multiples lasers systems Assessment of fusion quality during process Calibrated system for melting temperature monitoring CAD CT OT - OT is able to resolve diameters down to 0,2 mm (sure) 250 mm - Sizes down to 0,05 mm could be measured with image enhancement and some image processing *In cooperation with Carl Messtechnik 35

36 Products Development of automated inspections systems (RT, PT) on-demand CT-systems Analysis Software (acc. to AITM6-7006) Manufacturing of Reference Standards for RT and CT, also Image Quality Indicator (IQI) IQI for CT systems Ceramic Ball and Ball-bar for CT Systems signalto-noise and picture sharpness calibration 36

37 Conclusion 37

AM relevant fields Ongoing Developments - Online quality check of metal powder - Live NDT monitoring of printing process - Compilation of NDT and AM Process data - Automated Inspection systems e.

Feasibility - Computed Tomography (CT) - Radiography (Non-Film) (RT) - Penetrant Testing (PT) - Geometry Measurement (Online/Offline) - Process Monitoring (Shape-Check) NDT Training DT

38 AM relevant fields Ongoing Developments - Online quality check of metal powder - Live NDT monitoring of printing process - Compilation of NDT and AM Process data - Automated Inspection systems e.g. for PT, RT or CT - Reference Standards - Image Quality Indicator (IQI) - CT-System Analysis Software Quality Assurance Products Engineering & NDT Inspection AM Services Inspection & Feasibility - Computed Tomography (CT) - Radiography (Non-Film) (RT) - Penetrant Testing (PT) - Geometry Measurement (Online/Offline) - Process Monitoring (Shape-Check) NDT Training DT Inspection - Tensile tests - Compression tests - Shear tests - Metallography - Hardness tests - Fatigue tests - Fracture toughness tests - And more - X-Ray (Film / Non-Film) - All NDT Methods (EN4179, NAS-410) 38

39 Holger Speckmann CEO / Geschäftsführer Airbus Allee Bremen Germany T: M: holger.speckmann@airbus.com testia@airbus.com 39

Solutions at GE Inspection Technologies

Solutions at GE Inspection Technologies Business Overview Paul A. Meyer Our Company A global leader in technology-driven inspection solutions that deliver productivity, quality, and safety to our customers