idw – Informationsdienst Wissenschaft
Nachrichten, Termine, Experten
Nachrichten, Termine, Experten
Fraunhofer IZFP offers its customers and research partners the entire range of nondestructive testing technologies, whether it involves basic or applied research. The institute's researchers, engineers and technicians develop solutions to address modern testing applications including feasibility studies, consulting, training and inspection services and creating prototype systems. From June 13 to 17, 2016, our researchers and engineers will present the issue of on- and offline ultrasonic inspection of additively manufactured components at the 19th World Conference on Non-Destructive Testing (WCNDT) in Munich.
Additive manufacturing (AM) processes are based on localized melting of successive layers of powder. Different techniques are available for polymers and metals, where Selective Laser Melting (SLM) is one of the most prominent techniques for the production of metallic components. For titanium and nickel alloys, but also several austenitic stainless steels, additively manufactured parts can be produced with mechanical properties comparable to those of conventional cast parts. In comparison with conventional, subtractive manufacturing AM techniques provide considerably more freedom in designing and have a tremendous economic potential in view of saving resources.
Thus, AM is particularly interesting for the production of geometrically complex aero engine components. Such sophisticated components are manufactured at MTU from the heat-resistant nickel alloy Inconel 718. To comply with the high safety standards, quality assurance is pursued using various on- and offline techniques such as materials’ science investigations (metallographic inquiries, tensile tests) as well as nondestructive inspections. Online measurements are performed using optical tomography and ultrasound.
Our recent investigations have shown that the process parameter ‘laser power’ has a considerable influence on the microstructure of the manufactured component. In this respect, online recorded A-scans allow inferring conclusions about the quality of the SLM process - layer by layer. We report on experiments which have been performed to evaluate the least amount of porosity which can be detected during ultrasonic online monitoring. On the basis of the obtained results, we have developed a ‘smart’, additively manufactured test block for online process control and offline materials characterization using ultrasound. We show representative results and discuss their impact on future developments.
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