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Title: Porosity of additive manufacturing parts for process monitoring

Some metal additive manufacturing processes can produce parts with internal porosity, either intentionally (with careful selection of the process parameters) or unintentionally (if the process is not well-controlled.) Material porosity is undesirable for aerospace parts - since porosity could lead to premature failure - and desirable for some biomedical implants, since surface-breaking pores allow for better integration with biological tissue. Changes in a part's porosity during an additive manufacturing build may also be an indication of an undesired change in the process. We are developing an ultrasonic sensor for detecting changes in porosity in metal parts during fabrication on a metal powder bed fusion system, for use as a process monitor. This paper will describe our work to develop an ultrasonic-based sensor for monitoring part porosity during an additive build, including background theory, the development and detailed characterization of reference additive porosity samples, and a potential design for in-situ implementation.
Authors:
 [1] ;  [2]
  1. National Institute of Standards and Technology, Engineering Laboratory, Intelligent Systems Division, 100 Bureau Drive, Gaithersburg, MD 20899 (United States)
  2. National Institute of Standards and Technology, Engineering Laboratory, Materials and Structural Systems Division, 100 Bureau Drive, Gaithersburg, MD 20899 (United States)
Publication Date:
OSTI Identifier:
22263739
Resource Type:
Journal Article
Resource Relation:
Journal Name: AIP Conference Proceedings; Journal Volume: 1581; Journal Issue: 1; Conference: 40. annual review of progress in quantitative nondestructive evaluation, Baltimore, MD (United States), 21-26 Jul 2013, 10. international conference on Barkhausen noise and micromagnetic testing, Baltimore, MD (United States), 21-26 Jul 2013; Other Information: (c) 2014 American Institute of Physics; Country of input: International Atomic Energy Agency (IAEA)
Country of Publication:
United States
Language:
English
Subject:
46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND TECHNOLOGY; ADDITIVES; FABRICATION; MANUFACTURING; MONITORING; POROSITY; SENSORS