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Detection of Aberrations in Bulk Density in Additive Manufactured 300 M Steel using X-ray Radiographic Testing and Ultrasonic Testing

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Abstract

The laser additive manufacture (LAM) alloy fabrication process employs directed energy to fuse powder feedstock to produce a predetermined geometric form with unique microstructures and defects that are unlike other fabrication approaches. This study examines the efficacy for non-destructive inspection approaches to detect aberrations in bulk density (or defects) that are inherent in materials fabricated with a directed energy LAM process. Ultrasonic testing (UT) and radiographic testing (RT) are investigated for their capacity to detect seeded defects or deviations in bulk density within in LAM 300 M steel specimens. Intermittent adjustment of LAM hatch speed and hatch spacing is used to produce twelve 300 M steel specimens with bulk densities from 98 to 100%. A modified Archimedes’ method is used to measure relative (to wrought 300 M steel) bulk density. Densities from 98.22 to 99.85% were determined with a standard deviation of < 0.4% at a 95% confidence interval. UT and X-ray RT results showed clear qualitative differences between high and low-density LAM 300 M steel specimens and the full density 300 M wrought reference. UT A-Scans of LAM 300 M steel revealed multiple indications prior to and subsequent to the 1st backwall reflection and the absence of 3rd and 4th backwall reflection multiplets in LAM specimens. The UT A-scan signal amplitude threshold (with 5 and 10 MHz probes) is near 99.85% for detection of density aberrations in LAM 300 M steels. After refinement of the contrast in radiographic images, it was possible to use RT to detect defects in the specimens with bulk density up to 99.5%. Results provide insight into the development of non-destructive inspection procedures for in-situ process monitoring and qualifying parts.

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Data Availability

The datasets generated and/or analysed during the current study are available from the corresponding author on reasonable request.

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Acknowledgements

The authors would like to thank Dr. Xue of the National Research Council of Canada for specimen fabrication and Mr. Deering, Mrs. Hervé, Mr. Avery and Mr. Sanford from Defence Research and Development Canada for their assistance in preparing and testing specimens. This research was funded by the Canadian Federal Government through the Department of National Defence and the Department of Natural Resources Canada.

Funding

This research was funded by the Canadian Federal Government through the Department of National Defence and the Department of Natural Resources Canada.

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  1. Defence Research and Development Canada, Dartmouth, NS, B2Y 3Z7, Canada

    Shannon P. Farrell

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  1. Shannon P. Farrell
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Correspondence to Shannon P. Farrell.

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Farrell, S.P. Detection of Aberrations in Bulk Density in Additive Manufactured 300 M Steel using X-ray Radiographic Testing and Ultrasonic Testing. J Nondestruct Eval 40, 84 (2021). https://doi.org/10.1007/s10921-021-00814-5

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