<p class="MsoNormal" style="margin-bottom: .0001pt; line-height: normal">Certification of additively manufactured (AM) parts and qualification of AM processes, suppliers, and machines for aerospace applications involves significant mechanical testing, cost, and time. &nbsp;The AM community requires capabilities for fast, affordable and effective certification and qualification. These capabilities include the ability for rapid component and model validation, characterization of process and geometry impact on material properties, build and process monitoring capability, and effective non-destructive evaluation (NDE). Process Compensated Resonance Testing (PCRT) was identified as one of only two NDE methods that can inspect the full range of geometric complexity in parts made by AM [1]. PCRT uses the resonance frequencies of a component to rapidly detect defective parts, monitor build and processes and post-processing, characterize material properties, and can be used as a basis for model-validation [2-5]. This study examines the use of PCRT model-based inversion to nondestructively determine the material properties of AM titanium components. Samples were produced with intentional variations in build parameters, given a post-build surface treatment, machined into tensile coupons, and mechanically tested. PCRT data taken at each processing step was used to configure statistics-based PCRT inspections to provide process monitoring capability and the detection of sub optimal parts. Simultaneously, PCRT modeling tools were used to characterize AM material and dimensional properties through model inversion. This involved the creation of a PCRT forward model that was validated with measured resonance signatures from physical components. Then, a population of simulated components were generated with variation in properties over the range of the suspected printed variations. Finally, PCRT model inversion techniques were used to estimate the elastic properties of each printed part.</p>

Process Monitoring and Estimation of Material Properties of Additively Manufactured Components Using Model-Based Inversion of Process Compensated Resonance Testing (Pcrt) Data

Paper Proceedings: https://asmedigitalcollection.asme.org/qnde/QNDE2021/volume/85529

ASME 2021 48th Annual Review of Progress in Quantitative Nondestructive Evaluation (QNDE2021)

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