Unlocking the Full Potential of Reliable Additive Manufacturing with DR and CT
Additive Manufactured Parts: The Inspection Challenge
Additive Manufacturing (AM), or 3D printing, has revolutionized industries like aerospace, defense, and medical devices by enabling the creation of complex geometries and lightweight components. However, these same design freedoms introduce significant inspection challenges. Traditional nondestructive testing (NDT) methods such as ultrasonic testing (UT) and liquid penetrant testing (PT) often struggle with AM parts due to irregular surface textures, hidden internal structures, and intricate lattice designs.
So how can manufacturers ensure the quality and reliability of these critical components?
The answer lies in Digital Radiography (DR) and Computed Tomography (CT) X-ray Scanning.
Which is right for my application?
For AM quality control, use DR for quick, basic defect detection, and CT scanning for detailed 3D analysis and characterization of internal features and defects.
Digital Radiography:
- Strengths:
- Quick and cost-effective.
- Good for basic quality control and screening.
- Can be used for “pass/fail” assessments.
- Tradeoff:
- Provides a 2D view, limiting the ability to assess internal features.
- Less detailed than CT.
Computed Tomography:
- Strengths:
- 3D visualization of internal defects, porosity, and other features.
- Allows for quantitative analysis of defects and features.
- Can be used for CAD-to-part comparison and dimensional verification.
- Tradeoff:
- More time-consuming and expensive than DR.
- Requires specialized equipment and expertise.
Optimal use cases:
- Digital Radiography:
- When you need a quick and cost-effective method for part feature and defect detection.
- For basic quality control and screening.
- For “pass/fail” assessments.
- Computed Tomography:
- When you need a detailed 3D analysis of internal features and defects.
- When you need to quantify defects and features.
- For CAD-to-part comparison and other dimensional verification analysis tools.
- For parts with complex geometries or critical internal features.
Diving Deeper into CT for Additive Manufacturing
CT scanning has become the gold standard for inspecting AM parts because it provides comprehensive, non-destructive visualization of internal structures. Unlike traditional NDT methods, CT imaging offers a complete 3D representation, enabling engineers to detect defects, measure internal geometries, and validate production processes with precision.
Key Applications of CT in Additive Manufacturing:
- Defect Detection & Analysis: Identifies voids, porosity, and lack of fusion in metal and polymer AM parts.
- Melt/Fusion Analysis: Assesses material density and distribution to ensure proper fusion and strength.
- Wall Thickness Measurements: Detects inconsistencies in wall thickness, especially in critical aerospace and medical components.
- Dimensional Accuracy Checks: Compares scanned data against CAD files or known measurements to ensure tight tolerances.
- Failure Analysis: Helps manufacturers understand failure modes without destructive testing, preserving costly prototypes.
- Process Simulation Support: Generates precise data for software modeling, improving process efficiency.
When it comes to inspecting dense materials such as titanium, Inconel, and stainless steel, high-energy CT is essential. Traditional X-ray and lower-energy CT systems may struggle to penetrate these materials effectively. North Star Imaging’s high-energy CT systems and scanning services allow for deep penetration into dense metal parts while maintaining high resolution, making it possible to identify critical flaws in turbine blades, medical implants, and structural aerospace components.
Real-World Applications: How CT is Driving Quality in AM
CT technology is already proving invaluable in industries that rely on AM. Some key case studies include:
- Cooling Channels in Turbine Blades: CT scans help validate the integrity of complex cooling channels in aerospace engines, ensuring uniform airflow and heat dissipation.
- Surface Roughness: Identifying arithmetical mean height (Sa), and inconsistencies in AM parts to improve repeatability and manufacturing precision.
- Characterization of Metal Powders: Examining powder consistency and particle distribution to optimize material properties before the printing process begins.
- 3D Printed Rocket Nozzle: CT scans help validate the integrity of an AM rocket nozzle using ADR and segmentation of volumetric defects, metrology dimensional verification, and planar defect detection.
NSI’s Commitment to Industry Standards and Innovation
North Star Imaging is at the forefront of AM inspection, actively contributing to industry standards through multiple E07 (NDE) ASTM committees as well as F42 for AM. By shaping the future of AM testing standards, NSI ensures that its technology remains aligned with the latest industry best practices.
Why Choose NSI for Additive Manufacturing Inspection?
- Unparalleled Image Quality: Industry-leading DR and CT systems provide unmatched resolution for AM parts.
- High-Energy CT Capabilities: Ideal for inspecting dense materials used in aerospace and medical applications.
- Expert-Led Innovation: Active participation in ASTM committees ensures our technology meets and exceeds industry standards.
- Comprehensive Inspection Solutions: From defect detection to process simulation, as well as scanning services and training, NSI delivers a complete solution for AM quality control. NSI is here to support you every step of the way.
Take Your Additive Manufacturing Inspection to the Next Level
Whether you’re manufacturing high-performance aerospace or military components or life-saving medical devices, ensuring part integrity is critical. North Star Imaging is your trusted partner for advanced DR and CT solutions. We are directly supporting the industry to set the standards in the quickly changing manufacturing landscape and we are looking forward to using our expertise to help you navigate it.
Ready to optimize your AM inspection process? Contact us today to schedule a consultation or request a sample scan.