ndt challenges and solutions for metal additive ... · -all ndt methods (en4179, nas-410)-automated...
TRANSCRIPT
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1Testia GmbH
NDT Challenges and Solutions for
Metal Additive Manufactured (AM)
Parts & Structures
Space Tech Expo
Bremen, Germany, 24-26 October 2017
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2Testia GmbH
Everything starts with the
Process Map
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3Testia GmbH
Process Chain - AM
1• 3D-Model, Drawing
and Bill of Materials
2• Job Preparation
in Software
3• 3D-Printing (SLM)
4• Stress Relief
Heat Treatment
5• EDM Wire Cutting
6• Support Removal
7• Sand Blasting
8• Hot Isostatic Pressing
9• Non destructive testing
(µCT)
10• Machining / Polishing
11• Pickling /
Penetrant Testing
12• Final Inspection /
Marking / Packing
Source: Airbus/BDLI
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4Testia GmbH
Process Chain – AM – Quality/NDT
1• 3D-Model, Drawing
and Bill of Materials
2• Job Preparation
in Software
3• 3D-Printing (SLM)
4• Stress Relief
Heat Treatment
5• EDM Wire Cutting
6• Support Removal
7• Sand Blasting
8• Hot Isostatic Pressing
9• Non destructive testing
(µCT)
10• Machining / Polishing
11• Pickling /
Penetrant Testing
12• Final Inspection /
Marking / Packing
Source: Airbus/BDLI
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5Testia GmbH
NDT Simulation
1• 3D-Model, Drawing
and Bill of Materials
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6Testia GmbH
RT / CT-Simulation
Need for RT/CT-Simulation solution to analyze the inspectability
during the design process.
modeling & CT-simulation
flaw data
Analysis of CAD models and
components for synthetic
data
Definition of CT-simulation
environment and parameters
CAD designed AM
components and results,
inspectability
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7Testia GmbH
Powder Quality
3• 3D-Printing (SLM)
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8Testia GmbH
Powder Quality
Source:Airbus Spec: AIPS 01-04-020Additive Manufacturing – Powder Bed Fusion
Powder Quality is key for good part properties!
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9Testia GmbH
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
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10Testia GmbH
Non-Destructive-Testing (NDT)
9
• Non destructive testing (µCT)
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11Testia GmbH
Defect Catalogue
Defect catalogues for LB and EB Powder Bed Fusion
(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).
Defect type Location Description Visual FPI X-Ray CT Scan
External defects / distortion
External
Surface porosity, roughness, texture
External
Internal porosity Internal
Inclusion (foreignmaterial)
Internal / External
(external) (external)
Lack of fusion (unmoltenlayers)
Internal/external (external) (external)
No (1) No(1)
Source: Airbus
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12Testia GmbH
Acceptance Levels
Source:Airbus Spec: AIPS 01-04-020Additive Manufacturing – Powder Bed Fusion
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13Testia GmbH
Application of NDT
Source:Airbus Spec: AIPS 01-04-020Additive Manufacturing – Powder Bed Fusion
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14Testia GmbH
Defects to be detectedFailure Requirements stated in the AIMS and the AIPS:
100 µm!!≤3,2 µm
Source:Airbus Spec: AIPS 01-04-020 „Additive Manufacturing – Powder Bed Fusion“
Great challenge forsurface treatment
200 µm
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15Testia GmbH
Internal Defects – Digital X-Ray
9• Non destructive testing
(µCT)
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16Testia GmbH
X-Ray Non-Film / Digital X-Ray
Source: GE Inspection Technologies – Industrial Radiography
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17Testia GmbH
Internal Defects –
Computer Tomography (CT)
9• Non destructive testing
(µCT)
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18Testia GmbH
Different CT-MethodsC
om
pu
ted
To
mo
gra
ph
yL
am
ino
gra
ph
y Rotational-CTTranslational Laminography
Conventional-CT Helix-CT
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19Testia GmbH
Overview of „sample“ sizes
~ 20 mm
> 5000 mm
Micro Scale
Macro ScaleMacro+ Scale
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20Testia GmbH
One CT-Measurement and three Analyses
Porosity Wall-Thickness Geometric Deviation
260 mm
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21Testia GmbH
2D evaluation
AM-Part InspectionPore/Defect analysis
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22Testia GmbH
AM-Part Inspection
Crack analysis
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23Testia GmbH
Powder Residues
Foreign Particle Inspection
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24Testia GmbH
Geometrical Analysis
Online/Offline assessment:
– Thickness
– Shape
– Dimensions
Reverse Engineering
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25Testia GmbH
Used CT-Systems in Testia
Testia CT Micro
Focus
(Ottobrunn)
TESTIA CT System
(Ottobrunn)
Micro Focus CT /
Laminography*
Macro-CT* Mini Focus Robotic
RT (Dragonfly)*
High Energy CT*
X-Ray Source 225 kV X-RAY WorX XWT-300-
CT
300 kV
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 ---
Detector PerkinElmer
20x20 cm,
200 µm
Varian 4343 PerkinElmer
40x40 cm,
200 μm
PerkinElmer
40x40 cm,
200 μm
Fraunhofer XEye
40x20 cm,
100-350 μm
Row Detector
4000 cm
400 μm
Max. object
weight
10 kg < 50 kg 50 kg 150 kg 100 kg 10 000 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
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26Testia GmbH
External Defects –
Penetrant Testing (PT)
9• Non destructive testing
(µCT)
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27Testia GmbH
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
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28Testia GmbH
Automisation
9• Non destructive testing
(µCT)
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29Testia GmbH
Fully automated systems possible
– PT Systems
– X-Ray Turn-Key Solutions
– CT Turn-Key Solutions
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30Testia GmbH
TestingMechanical, Physical, Chemical, etc
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31Testia GmbH
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
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32Testia GmbH
Online Monitoring End-to-End
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33Testia GmbH
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
Connected Data Analytics
„Chain Apps“ collect and analyze data of
production and may relate it to NDT data.
Production Data
Sensor Systems monitor production
quality and record every defect.
NDT Data
NDT Department generates test data of
finished parts.
*In cooperation with InFactory
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34Testia GmbH
Other relevant topics
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35Testia GmbH
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
0
.2
0
.3 0
.2
0
.1
0
.05
CAD CT OT
- OT is able to resolve diameters down to 0,2 mm (sure)
- Sizes down to 0,05 mm could be measured with image
enhancement and some image processing250 mm
*In cooperation with Carl Messtechnik
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36Testia GmbH
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 signal-
to-noise and picture sharpness calibration
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37Testia GmbH
Conclusion
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38Testia GmbH
AM relevant fields
AM Services
Engineering
& NDT Inspection
DT Inspection
NDT Training
Products
Quality Assurance
Inspection & Feasibility - Computed Tomography (CT)
- Radiography (Non-Film) (RT)
- Penetrant Testing (PT)
- Geometry Measurement (Online/Offline)
- Process Monitoring (Shape-Check)
- 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)
- Automated Inspection
systems e.g. for
PT, RT or CT
- Reference Standards
- Image Quality
Indicator (IQI)
- CT-System Analysis
Software
Ongoing Developments- Online quality check of metal powder
- Live NDT monitoring of printing
process
- Compilation of NDT and AM Process
data
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39Testia GmbH
Holger SpeckmannCEO / Geschäftsführer Testia GmbH
Airbus Allee 1
28199 Bremen
Germany
T: +49 421 538 4823
M: +49 151 16 70 09 15
eMail:[email protected]