Quality control for metallic components manufactured by powder bed fusion

Speaker:
Milne, Katy; The Manufacturing Technology Centre; United Kingdom

Authors:
Milne, K.; The Manufacturing Technology Centre; United Kingdom
Dutton, B.; The Manufacturing Technology Centre; United Kingdom
Brierley, N.; The Manufacturing Technology Centre; United Kingdom
Smith, S.; The Manufacturing Technology Centre; United Kingdom

ID: ECNDT-0999-2018
Session: Additive Manufacturing – radiographic methods
Room: H1
Date: 2018-06-11
Time: 13:30 - 13:50

The rate of adoption of metal powder bed fusion technologies is accelerating. According to Wohlers (1), between 2014 and 2015, revenue of sales for metal powder to the AM sector grew by 80.9% to an estimated sales value of $88.1m. GE Aviation began to manufacture fuel nozzles for their LEAP engine in 2016 (2).

Quality assurance is one of the barriers to adoption of additive manufacturing (1). General approaches and tools exist for determining process variables and deriving a quality control plan (3), including Taguchi methods, Failure Mode Effects Analysis etc. Examples of the application of these approaches to metal powder bed fusion will be given.

Whilst these general approaches for determining a quality control plan exist, each new manufacturing process does have unique characteristics, which can result in new challenges (or opportunities) for non-destructive testing. Here, three characteristics of metal powder bed fusion will be described and their implications for non-destructive testing discussed:

  • New / process specific defect types and morphologies
  • Complexity of geometry
  • Data driven process