Optimization of digital radiography for large metallic additively manufactured components
ISSN: 1355-2546
Article publication date: 14 January 2020
Issue publication date: 3 April 2020
Abstract
Purpose
The continued improvement of additive manufacturing (AM) processing has led to increased part complexity and scale. Processes such as electron beam directed energy deposition (DED) are able to produce metal AM parts several meters in scale. These structures pose a challenge for current inspection techniques because of their large size and thickness. Typically, X-ray computed tomography is used to inspect AM components, but low source energies and small inspection volumes restrict the size of components that can be inspected. This paper aims to develop digital radiography (DR) as a method for inspecting multi-meter-sized AM components and a tool that optimizes the DR inspection process.
Design/methodology/approach
This tool, SMART DR, provides optimal orientations and the probability of detection for flaw sizes of interest. This information enables design changes to be made prior to manufacturing that improve the inspectabitity of the component and areas of interest.
Findings
Validation of SMART DR was performed using a 40-mm-thick stainless-steel blade produced by laser-based DED. An optimal orientation was automatically determined to allow radiographic inspection of a thickness of 40 mm with a 70% probability of detecting 0.5 mm diameter flaws. Radiography of the blade using the optimal orientation defined by SMART DR resulted in 0.5-mm diameter pores being detected and indicated good agreement between SMART DR’s predictions and the physical results.
Originality/value
This paper addresses the need for non-destructive inspection techniques specifically developed for AM components.
Keywords
Acknowledgements
The authors would like to acknowledge the support of the Defense Advanced Research Projects Agency for funding of this work under award DARPA HR001-15-C-0029. The views, opinions and/or findings expressed are those of the authors and should not be interpreted as representing the official views or policies of the Department of Defense or the US Government.
Citation
Stoner, B.E., Jones, G.T., Joshi, S. and Martukanitz, R. (2020), "Optimization of digital radiography for large metallic additively manufactured components", Rapid Prototyping Journal, Vol. 26 No. 3, pp. 531-537. https://doi.org/10.1108/RPJ-04-2018-0107
Publisher
:Emerald Publishing Limited
Copyright © 2019, Emerald Publishing Limited