Additive manufacturing and non-destructivetesting of topology-optimised aluminiumcomponents

Publikation, 2020


S. Senck, M. Happl, M. Reiter, M. Scheerer, M. Kendel, J. Glinz, J. Kastner - Additive manufacturing and non-destructivetesting of topology-optimised aluminiumcomponents - Nondestructive Testing and Evaluation, Vol. 35, No. 3, 2020, pp. 315-327


Additive manufacturing (AM) unlocks novel industrial possibilities in relation to design optimisation for lightweight structures, e.g. in aero-space applications. However, the inherent geometric complexity of topology-optimised AM components represents a major challenge for conventional non-destructive testing (NDT) methods. Due to its flexibility and high throughput, industrial X-ray micro-computed tomography (XCT) is the most promising NDT method for AM. In this contribution, we investigate topology-optimised engine brackets that were manufac-tured from AlSi10 Mg using selective laser melting (SLM). We investigate the respective parts and in-process test coupons in a multiscale approach to be able to extract pore size distributions at different spatial resolutions between 105 and 1.25 μm isometric voxel size. At the lowest spatial resolutions, existing pores cannot be segmented. In contrast, decreasing voxel sizes leads to an increase in total porosity up to 1.53%. Defects like pores in load-carrying areas can profoundly influence the component ́s mechanical performance; hence, extensive NDT investigations are man-datory to predict the effect of defects in aluminium AM components.