Capability Assessment of X-Ray Computed Tomography for the Inspection of Metal Additive Manufactured Products

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Precision ADM (PADM) Inc., based in Winnipeg, uses Additive Manufacturing (AM) technology to manufacture high-value components for the medical, aerospace, energy, and industrial sectors. PADM is the first private sector metals AM Company in the Manitoba region and has an established local and global presence in the field. Metal AM processes are considerably complex, and as such, components produced with this technology can suffer from some process-related defects. Defects such as porosity, cracks, and structural distortion are routinely found in the finished AM parts, thereby compromising the functional integrity of such components. Critical components, such as those used for aerospace and medical applications, usually require careful inspection in order to meet stringent safety requirements. PADM has adopted other inspection techniques including metallography and microscopy, for analyzing the AM products, and has sent samples hundreds of miles away for 2D X-Ray and other analysis. The acquisition of a new X-Ray Computed Tomography (X-Ray CT) Capability at Red River College (RRC) presents a unique opportunity for PADM to evaluate this technology for parts inspection. The X-Ray CT system will help in the comprehensive analysis of internal cavities, porosities, and dimension of parts with complex geometries. To obtain quality X-Ray CT scan that is required for high defect detectability and accurate dimensional analysis, capability assessment and best-practice guidelines for the system need to be established for metal AM products. PADM is collaborating with RRC's Technology Access Centre for Aerospace and Manufacturing (TACAM) to evaluate X-Ray CT, develop capability and establish guidelines for the inspection and qualification of AM parts. This will involve determining the minimum detectable defect size and dimensional accuracy for different AM materials, thicknesses, and geometry variations. Standard specimens of commonly used metallic AM materials will be produced by PADM, using their directed metal laser sintering (DMLS) AM systems, which