Quality monitoring by in-sity defect monitoring for high performance lasr powder bed fusion processing of Alloy 718

MSE 2024

Lecture

26.09.2024 (CEST)

Prof. Dr. Lars Nyborg

Chalmers University of Technology

Nyborg, L. (Speaker)¹; Calmunger, M.²; Delin, M.³; Gulisano, V.¹; Gårdstam, J.⁴; Riabov, D.⁵; Schwerz, C.¹; Sievers, E.¹; Xu, J.²

¹Chalmers University of Technology, Göteborg (Sweden); ²Linköping University; ³GKN Aerospace Sweden, Trollhättan (Sweden); ⁴Quintus Technologies, Västerås (Sweden); ⁵Höganäs AB

Additive Fertigung

Künstliche Intelligenz

Fertigung und Produktionstechnik

Forschung und Entwicklung

Heißisostatisches Pressen

maschinelles Lernen

Laser-Pulverbettfusion

In-situ Fehlerüberwachung

Optische Tomographie

Ermüdungstest

Legierung 718

Vorschau

24 Min. Untertitel (CC)

Powder bed fusion - laser beam allows manufacture of high performance like nickel base alloys in advanced geometrical design. Oven it is possible to optimize a process by proper choice of print parameters to reach nominally full density. Still, even if there is an optimised process it is not sure that this means that there is defect-free printing in all parts of a component. One critical reason for this is so-called stochastic processes that arise owing to for example spatter generations. Such processes lead to incorporation of hot particles in the parts being built and lead to lack-of-fusion typ of detects despite that the processing is done with optimized printing parameters. This challenge calls for the application of on-line process monitoring to mitigate and control such events. In this communication, results are presented for Alloy 718, how on-line monitoring with so-called optical tomography (OT) can be applied to depict the formation of spatter phenomena with aid of ML-approaches. The OT data are correlated with post-mortem XCT measurement and categories with high and minimum amount of spatter-generated defects are produced on purpose. Normally, depicting role of defects is hardly possible to do by static mechanical testing, owing to the fact that the defect density (when too high) that it would provide any impact on properties like yield strength, ultimate tensile strength or even ductility. Hence, this is why in this communication, we focus on fatigue properties as correlative properties to the defect control. The presentation will provide results for defect-free and defect-containing builds which afterwards have gone through solutionising and ageing for Alloy 718 as well as such heat treatment integrated in hot isostatic pressing. The key homemake will be how we can provide a strategy for first part right capacity and depict defect formation in-line with higher precision and latency that ever is possible by checking parts after manufacture with techniques as XCT, etc.