Title: Powder-based additive manufacturing - a review of types of defects, generation mechanisms, detection, property evaluation and metrology

Authors: Hossein Taheri; Mohammad Rashid Bin Mohammad Shoaib; Lucas W. Koester; Timothy A. Bigelow; Peter C. Collins; Leonard J. Bond

Addresses: Center for Nondestructive Evaluation (CNDE), Applied Science Complex II, 1915 Scholl Road, Ames, IA 50011, USA; Department of Mechanical Engineering, Iowa State University, Ames, IA 50011, USA ' Department of Aerospace Engineering, Iowa State University, Ames, IA 50011, USA ' Center for Nondestructive Evaluation (CNDE), Applied Science Complex II, 1915 Scholl Road, Ames, IA 50011, USA ' Center for Nondestructive Evaluation (CNDE), Applied Science Complex II, 1915 Scholl Road, Ames, IA 50011, USA; Department of Mechanical Engineering, Iowa State University, Ames, IA 50011, USA ' Department of Materials Science and Engineering, Iowa State University, Ames, IA 50011, USA; Center for Advanced Non-Ferrous Structural Alloys (CANFSA), Ames, IA 50011, USA ' Center for Nondestructive Evaluation (CNDE), Applied Science Complex II, 1915 Scholl Road, Ames, IA 50011, USA; Department of Mechanical Engineering, Iowa State University, Ames, IA 50011, USA; Department of Aerospace Engineering, Iowa State University, Ames, IA 50011, USA

Abstract: Powder-based additive manufacturing (AM) technologies have been evaluated for use in different fields of application (aerospace, medical, etc.). Ideally, AM parts should be at least equivalent, or preferably better quality than conventionally produced parts. Manufacturing defects and their effects on the quality and performance of AM parts are a currently a major concern. It is essential to understand the defect types, their generation mechanisms, and the detection methodologies for mechanical properties evaluation and quality control. We consider the various types of microstructural features or defects, their generation mechanisms, their effect on bulk properties and the capability of existing characterisation methodologies for powder based AM parts in this work. Methods of in-situ non-destructive evaluation and the influence of defects on mechanical properties and design considerations are also reviewed. Together, these provide a framework to understand the relevant machine and material parameters, optimise the process and production, and select appropriate characterisation methods.

Keywords: additive manufacturing; process evaluation; quality control; defects; inspection; in-line monitoring; non-destructive testing; NDT; design standards; mechanical properties.

DOI: 10.1504/IJASMM.2017.088204

International Journal of Additive and Subtractive Materials Manufacturing, 2017 Vol.1 No.2, pp.172 - 209

Received: 26 Aug 2016
Accepted: 20 Feb 2017

Published online: 29 Nov 2017 *

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