Non-destructive quality control methods in additive manufacturing: a survey

Abstract

Purpose

In recent years, additive manufacturing (AM) technology has been acknowledged as an efficient method for producing geometrical complex objects with a wide range of applications. However, dimensional inaccuracies and presence of defects hinder the broad adaption of AM procedures. These factors arouse concerns regarding the quality of the products produced with AM and the utilization of quality control (QC) techniques constitutes a must to further support this emerging technology. This paper aims to assist researchers to obtain a clear sight of what are the trends and what has been inspected so far concerning non-destructive testing (NDT) QC methods in AM.

Design/methodology/approach

In this paper, a survey on research advances on non-destructive QC procedures used in AM technology has been conducted. The paper is organized as follows: Section 2 discusses the existing NDT methods applied for the examination of the feedstock material, i.e. incoming quality control (IQC). Section 3 outlines the inspection methods for in situ QC, while Section 4 presents the methods of NDT applied after the manufacturing process i.e. outgoing QC methods. In Section 5, statistical QC methods used in AM technologies are documented. Future trends and challenges are included in Section 6 and conclusions are drawn in Section 7.

Findings

The primary scope of the study is to present the available and reliable NDT methods applied in every AM technology and all stages of the process. Most of the developed techniques so far are concentrated mainly in the inspection of the manufactured part during and post the AM process, compared to prior to the procedure. Moreover, material extrusion, direct energy deposition and powder bed processes are the focal points of the research in NDT methods applied in AM.

Originality/value

This literature review paper is the first to collect the latest and the most compatible techniques to evaluate the quality of parts produced by the main AM processes prior, during and after the manufacturing procedure.

Citation

Charalampous, P., Kostavelis, I. and Tzovaras, D. (2020), "Non-destructive quality control methods in additive manufacturing: a survey", Rapid Prototyping Journal, Vol. 26 No. 4, pp. 777-790. https://doi.org/10.1108/RPJ-08-2019-0224