Additive Manufacturing Crack Standards for Reliable NDT Calibration
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Solution Overview
Problem
Existing non-destructive testing (NDT) methods for crack defects in additive manufacturing components face challenges due to structural differences between additive and traditional parts, leading to poor accessibility, large testing blind areas, and inaccurate calibration signals, with manufacturing methods for standard parts causing structural damage and inconsistent crack formation.
Innovation Solution
A method for manufacturing a crack defect standard part using additive manufacturing processes with specific process parameters, such as laser selective melting, to create crack defects that accurately reflect those in additive manufacturing workpieces, followed by NDT to obtain calibration signals and mechanical property relationships.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional NDT methods are used on additive manufacturing workpieces, then the testing process can be performed, but poor accessibility and large testing blind areas occur due to complex geometry and anisotropy
Solution Approach 1:
The patent changes the geometric parameters of the standard part by designing a simplified structure with reduced complexity compared to actual workpieces. This parameter change enables better accessibility for NDT equipment while maintaining representative crack defect features for calibration purposes.
2Manufacturing precision
If fatigue testing or plasma cutting methods are used to manufacture standard parts with crack defects, then crack defects can be introduced, but the structure of the standard part is damaged significantly and mechanical testing cannot be performed
Solution Approach 1:
The patent applies preliminary action by designing crack defects directly into the 3D model before additive manufacturing. This allows crack defects to be created during the manufacturing process itself, eliminating the need for post-manufacturing damage introduction methods that would compromise structural integrity.
Solution Approach 2:
The patent utilizes the phase transition characteristics of metal powder during additive manufacturing (melting and solidification) to naturally form crack defects through controlled process parameters, avoiding mechanical damage methods while preserving structural integrity.
3Manufacturing precision
If additive manufacturing is used to manufacture standard parts with designed crack shapes, then crack defects similar to actual workpieces can be obtained, but it is difficult to form cracks due to powder retention in wide cracks or metal filling in narrow cracks
Solution Approach 1:
The patent changes the additive manufacturing process parameters (laser power, scanning speed, hatching distance, layer thickness) to create optimal conditions for crack formation. By adjusting these parameters, cracks can form naturally during manufacturing without powder retention or metal filling issues.
Solution Approach 2:
The patent creates a simplified copy of the actual workpiece structure for the standard part, maintaining representative crack defect features while using a geometry that is easier to manufacture with reliable crack formation through additive manufacturing process control.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The method enables accurate and reliable NDT of crack defects in additive manufacturing workpieces, improving the accuracy and reliability of NDT results and the understanding of crack defect-mechanical property relationships.
Implementation Method 1
selective laser melting (SLM) is considered to be one of the most potential AM technologies. Because laser beam with fine focusing spot is used as forming energy source
Implementation Method 2
Due to the complex phase transformation process of rapid melting and solidification of metal powder materials in SLM process
Implementation Method 3
uneven temperature field caused by local heat input will inevitably cause local thermal effect, so the molten pool will bear the role of tensile stress during solidification and subsequent cooling, and form residual stress in subsequent process, which eventually leads to the generation of cracks
Data Source
AI summary
A non-destructive testing method for crack defects, and a testing standard part and a manufacturing method thereof, used for the non-destructive testing of crack defects of an additive manufacturing workpiece. The manufacturing method of the crack defect standard part comprises: step A, setting a crack defect area of the standard part, in the crack defect area, the proportion of the crack defects in the crack defect area is set as a first proportion value; step B, selecting an additive manufacturing forming process for manufacturing the crack defect area to obtain a first process parameter of the additive manufacturing forming process corresponding to the first proportion value; and step C, performing the additive manufacturing forming process based on the first process parameter to form the crack defect area. The non-destructive testing method for crack defects of the present invention has the advantages of accurate and reliable testing results.