Additive manufacturing (AM) unlocks novel industrial possibilities in relation to design optimisation for lightweight structures, e.g. in aerospace applications. However, the inherent geometric complexity of topology-optimised AM components represents a major challenge for conventional non-destructive testing (NDT) methods. Due to its flexibility and high throughput, industrial X-ray micro-computed tomography (XCT) is the most promising NDT method for AM. In this contribution, we investigate topology-optimised engine brackets that were manufactured from AlSi10 Mg using selective laser melting (SLM). We investigate the respective parts and in-process test coupons in a multiscale approach to be able to extract pore size distributions at different spatial resolutions between 105 and 1.25 µm isometric voxel size. At the lowest spatial resolutions, existing pores cannot be segmented. In contrast, decreasing voxel sizes leads to an increase in total porosity up to 1.53%. Defects like pores in load-carrying areas can profoundly influence the component´s mechanical performance; hence, extensive NDT investigations are mandatory to predict the effect of defects in aluminium AM components.

X-ray Computed Tomography (CT) in combination with a tensile/compression stage can deliver great insights in the damage mechanisms of a material. As the material properties change at low and high temperatures, materials may perform differently as they do at room temperature. In this paper, a novel Mechanical In-situ Stage with Temperature control (MIST) for the usage in laboratory CT devices for high resolution - (3 μm)³ - acquisitions is presented. Since the specimen temperature is controlled by air flow, the MIST stage is suitable for testing polymers and allows cooling and heating in one test cycle (-10 °C to +100 °C). The MIST stage is a modification of the CT500 DEBEN tensile/compression stage. It enables mechanical tests that combine the application of force and temperature on a sample at the same time. A technical description of the developed stage is presented. Furthermore, its advantages compared to existing devices are explored and application fields of the MIST are shown.