A review on qualification and certification for metal additive manufacturing

Chen, Ze; Han, Changjun; Gao, Ming; Kandukuri, Sastry Yagnanna; Zhou, Kun

doi:10.1080/17452759.2021.2018938

Cited by 87 publications

(25 citation statements)

References 47 publications

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“…CT offers many advantages in the inspection of 3D-printed products and processes; however, there is a limitation in micrometer-scaled measurements. The inspection method for geometry or internal defects of 3D-printed products in real-time during printing or after fabrication has not been standardized yet 34 – 36 . Nevertheless, CT is a good inspection tool for non-destructive testing 37 ; internal pores and porosity are detected without destruction, but micrometer-scaled measurements are not reproducible.…”

Section: Discussionmentioning

confidence: 99%

Fabrication of a lattice structure with periodic open pores through three-dimensional printing for bone ingrowth

Park

Kim

et al. 2022

Sci Rep

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Lattice structures for implants can be printed using metal three-dimensional (3D)-printing and used as a porous microstructures to enhance bone ingrowth as orthopedic implants. However, designs and 3D-printed products can vary. Thus, we aimed to investigate whether targeted pores can be consistently obtained despite printing errors. The cube-shaped specimen was printed with one side 15 mm long and a full lattice with a dode-thin structure of 1.15, 1.5, and 2.0 mm made using selective laser melting. Beam compensation was applied, increasing it until the vector was lost. For each specimen, the actual unit size and strut thickness were measured 50 times. Pore size was calculated from unit size and strut thickness, and porosity was determined from the specimen’s weight. The actual average pore sizes for 1.15, 1.5, and 2.0 mm outputs were 257.9, 406.2, and 633.6 μm, and volume porosity was 62, 70, and 80%, respectively. No strut breakage or gross deformation was observed in any 3D-printed specimens, and the pores were uniformly fabricated with < 10% standard deviation. The actual micrometer-scaled printed structures were significantly different to the design, but this error was not random. Although the accuracy was low, precision was high for pore cells, so reproducibility was confirmed.

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Section: Discussionmentioning

confidence: 99%

Fabrication of a lattice structure with periodic open pores through three-dimensional printing for bone ingrowth

Park

Kim

et al. 2022

Sci Rep

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“…In addition, through this consistency we are able to provides accurate quantification of flaws, shape, size/morphology, and study their impact on the mechanical performance and properties of the printed part. This is a major step toward qualification and certification of AM parts that has historically been a bottleneck preventing AM from reaching full potential 51 .…”

Section: Discussionmentioning

confidence: 99%

Enabling Rapid X-ray CT Characterisation for Additive Manufacturing Using CAD models and Deep Learning-based Reconstruction

Ziabari

Singanallur²,

Snow

et al. 2022

Preprint

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Metal additive manufacturing (AM) offers significant opportunities for flexible, efficient, and cost-effective printing of highly complex parts. Despite recent successes, metal AM is still limited to relatively few alloys. In order to qualify new alloys for metal AM, process parameters must be optimised to produce high-quality and consistent components. However, process parameter optimisation is often a challenging and cost-prohibitive task. In this work, we propose a novel, deep learning-based approach that allows for fast, high-quality, non-destructive characterisation of AM parts from sparse X-ray computed tomography (CT) measurements. The proposed approach rapidly produces high-quality reconstructions from fast X-ray CT scans of metal AM parts by leveraging digital models of the component and physics-based simulations of nonlinear interactions between X-ray radiation and metals, significantly reducing beam hardening, metal, and other common X-ray CT artifacts. The method allows for batch characterisation of hundreds of AM parts printed on the same plate with different printing parameters, paving the way for identifying the optimum printing parameters for new AM materials. We present results for an experimental case study illustrating the practical utility of our method. The proposed approach not only produced accurate 3D volumetric reconstruction images of the parts from their respective sparsely measured X-ray CT scans but also resulted in both a 300% reduction in total scan time and more than 4X improvement in probability of flaw detection in post-processing analysis of the data. This has enabled us to rapidly search for and identify useful process parameters that can lead to high-quality parts made from a novel AlCe alloy.

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“…The main barrier to the large-scale adoption of these technologies in the industry is the limited availability of regulations covering the different aspects of AM, including raw material quality, design guidelines, fabrication and postprocessing techniques, material testing, and inspection of the final components. This obliges companies to make considerable efforts in terms of investigation and testing to qualify and certify AM products prior to market launch, which may result in extremely high costs and long lead times [53]. In addition, compared to traditional fabrication methods, AM processes often exhibit poor repeatability and reproducibility [54,55], and the relationship between manufacturing route, material characteristics, and final product quality still needs to be thoroughly explored [53].…”

Section: Applications Of Additively Manufactured Pure Copper Componentsmentioning

confidence: 99%

“…This obliges companies to make considerable efforts in terms of investigation and testing to qualify and certify AM products prior to market launch, which may result in extremely high costs and long lead times [53]. In addition, compared to traditional fabrication methods, AM processes often exhibit poor repeatability and reproducibility [54,55], and the relationship between manufacturing route, material characteristics, and final product quality still needs to be thoroughly explored [53].…”

Section: Applications Of Additively Manufactured Pure Copper Componentsmentioning

confidence: 99%

Additive Manufacturing of Pure Copper: Technologies and Applications

Romano¹,

Vedani²

2023

Copper - From the Mineral to the Final Application

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The opportunity to process pure copper through additive manufacturing has been widely explored in recent years, both in academic research and for industrial uses. Compared to well-established fabrication routes, the inherent absence of severe design constraints in additive manufacturing enables the creation of sophisticated copper components for applications where excellent electrical and thermal conductivity is paramount. These include electric motor components, heat management systems, heat-treating inductors, and electromagnetic devices. This chapter discusses the main additive manufacturing technologies used to fabricate pure copper products and their achievable properties, drawing attention to the advantages and the challenges they have to face considering the peculiar physical properties of copper. An insight on the topic of recycling of copper powders used in additive manufacturing is also provided. Finally, an overview of the potential areas of application of additively manufactured pure copper components is presented, highlighting the current technological gaps that could be filled by the implementation of additive manufacturing solutions.

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A review on qualification and certification for metal additive manufacturing

Cited by 87 publications

References 47 publications

Fabrication of a lattice structure with periodic open pores through three-dimensional printing for bone ingrowth

Fabrication of a lattice structure with periodic open pores through three-dimensional printing for bone ingrowth

Enabling Rapid X-ray CT Characterisation for Additive Manufacturing Using CAD models and Deep Learning-based Reconstruction

Additive Manufacturing of Pure Copper: Technologies and Applications

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