Standard method for microCT-based additive manufacturing quality control 1: Porosity analysis.

Area of Science:

• Materials Science
• Non-destructive Testing
• Additive Manufacturing

Background:

• Micro-computed tomography (MicroCT) is crucial for non-destructive internal analysis, particularly for void and porosity assessment.
• Lack of standardized methods for additive manufacturing (AM) hinders comparable porosity analysis due to variations in part geometry, scan resolution, and image processing.
• Existing MicroCT approaches yield incomparable results for AM parts, impeding process optimization.

Purpose of the Study:

• To establish a standardized 10mm cube coupon sample and workflow for MicroCT-based porosity analysis in additive manufacturing.
• To enable directly comparable porosity data across different samples and AM systems.
• To correlate pore morphology with specific process defects for improved AM quality control.

Main Methods:

• Development of a simplified 10mm cube-shaped coupon sample for MicroCT scanning.
• Implementation of a streamlined workflow for porosity quantification and void characterization.
• Application of the standardized method to analyze characteristic voids in AM parts, including lack of fusion and build-direction pores.

Main Results:

• The standardized MicroCT method provides directly comparable porosity information from different AM samples and systems.
• The workflow successfully quantifies porosity and identifies distinct void types, such as sub-surface lack of fusion and tree-like pores.
• Demonstrated capability to link specific void morphologies to potential process parameter issues.

Conclusions:

• A standardized MicroCT method using a 10mm cube sample offers a reliable approach for quantitative porosity analysis in additive manufacturing.
• This standardization facilitates inter-system comparisons and aids in identifying process-related defects.
• The method supports MicroCT's role in optimizing AM processes by enabling detailed void characterization and correlation with manufacturing parameters.