Advanced Manufacturing and Nondestructive Testing Techniques

A special issue of Applied Sciences (ISSN 2076-3417). This special issue belongs to the section "Additive Manufacturing Technologies".

Deadline for manuscript submissions: 20 July 2024 | Viewed by 2437

Special Issue Editor


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Guest Editor
French National Metrology Institute (NMI), Laboratoire National de Métrologie et d’Essais (LNE), 75015 Paris, France
Interests: additive manufacturing; nondestructive testing; metrology

Special Issue Information

Dear Colleagues,

Metallic additive manufacturing (AM) is gaining in popularity in the industry (aerospace, defense, nuclear, etc.) and in the medical sector, particularly the powder bed fusion (PBF) and the directed energy deposition (DED) categories of processes. In such critical sectors, the integrity and geometrical conformity to the numerical design of the manufactured parts need to be demonstrated.

First, to limit the defects and deviations from the numerical design, the implementation of digital twins of the AM process chain is a solution. Second, to limit the defects during the AM process, the monitoring of the process, coupled with a feedback loop, involving artificial intelligence (AI), is a solution. Third, to detect defects and deviations in the post-process AM parts, non-destructive testing (NDT) and metrology are required. However, the complexity in shape enabled by AM, including internal structures and the rough surface finish, poses a challenge to the quality control of AM parts. X-ray Computed Tomography (XCT), implementing cone beam or synchrotron radiation, is the most performing NDT method as it enables NDT and metrology. However, linear and nonlinear Resonant Ultrasound Spectroscopy (RUS), swept sine methods and Impulse Excitation Method (IEM), are alternative very performing methods for NDT. Moreover, considering dense and large DED parts, tomosynthesis and Phased Array Ultrasonic Testing (PAUT) are more adapted. In addition, the potential for inspection of these NDT methods can be increased by the implementation of IA, allowing the operator's influence to be limited.

Dr. Anne Francoise Obaton
Guest Editor

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Keywords

  • additive manufacturing (AM)
  • powder bed fusion (PBF)
  • directed energy deposition (DED)
  • process monitoring
  • digital twins
  • nondestructive testing (NDT)
  • metrology
  • artificial intelligence (AI)
  • X-ray computed tomography (XCT)
  • synchrotron
  • tomosynthesis
  • resonant ultrasound spectroscopy (RUS)
  • swept sine methods
  • impulse excitation method (IEM)
  • nonlinear RUS
  • phased array ultrasonic testing (PAUT)

Published Papers (2 papers)

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Research

15 pages, 8526 KiB  
Communication
Controlled Creation of Contact Cracks in Additive Manufactured Components
by Daniel Preston, Ahmed Ashour, Julian Wright, James Watts, Daniel Sanmartin and Jacques Wood
Appl. Sci. 2023, 13(21), 11990; https://doi.org/10.3390/app132111990 - 02 Nov 2023
Viewed by 897
Abstract
Techniques for the controlled seeding and growth of cracks are urgently required for non-destructive testing technique evaluation, particularly for additive manufactured (AM) samples. This paper describes a method that uses a combination of the tensile load and the resonance excitation of notched AM [...] Read more.
Techniques for the controlled seeding and growth of cracks are urgently required for non-destructive testing technique evaluation, particularly for additive manufactured (AM) samples. This paper describes a method that uses a combination of the tensile load and the resonance excitation of notched AM samples, with in situ monitoring of the resonance frequency serving to track the crack dimensions. Mechanical low-cycle fatigue cracks, ranging in length from ~0.3 mm to ~5 mm, were successfully created in five AM samples using this technique. The samples were non-destructively characterized using optical microscopy and Nonlinear Resonance (NLR) testing. The exploitation of resonance enabled the concentration of a significant number of stress cycles on the samples in much shorter timespans than conventional fatigue testing, enabling a high throughput while utilizing compact components. Furthermore, the tracking of the resonance frequency shift throughout the process enabled non-invasive and no-contact real-time condition monitoring. Full article
(This article belongs to the Special Issue Advanced Manufacturing and Nondestructive Testing Techniques)
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18 pages, 7111 KiB  
Article
In Vivo Bone Progression in and around Lattice Implants Additively Manufactured with a New Titanium Alloy
by Anne-Françoise Obaton, Jacques Fain, Dietmar Meinel, Athanasios Tsamos, Fabien Léonard, Benoît Lécuelle and Madjid Djemaï
Appl. Sci. 2023, 13(12), 7282; https://doi.org/10.3390/app13127282 - 19 Jun 2023
Cited by 3 | Viewed by 1021
Abstract
The osseointegration in/around additively manufactured (AM) lattice structures of a new titanium alloy, Ti–19Nb–14Zr, was evaluated. Different lattices with increasingly high sidewalls gradually closing them were manufactured and implanted in sheep. After removal, the bone–interface implant (BII) and bone–implant contact (BIC) were studied [...] Read more.
The osseointegration in/around additively manufactured (AM) lattice structures of a new titanium alloy, Ti–19Nb–14Zr, was evaluated. Different lattices with increasingly high sidewalls gradually closing them were manufactured and implanted in sheep. After removal, the bone–interface implant (BII) and bone–implant contact (BIC) were studied from 3D X-ray computed tomography images. Measured BII of less than 10 µm and BIC of 95% are evidence of excellent osseointegration. Since AM naturally leads to a high-roughness surface finish, the wettability of the implant is increased. The new alloy possesses an increased affinity to the bone. The lattice provides crevices in which the biological tissue can jump in and cling. The combination of these factors is pushing ossification beyond its natural limits. Therefore, the quality and speed of the ossification and osseointegration in/around these Ti–19Nb–14Zr laterally closed lattice implants open the possibility of bone spline key of prostheses. This enables the stabilization of the implant into the bone while keeping the possibility of punctual hooks allowing the implant to be removed more easily if required. Thus, this new titanium alloy and such laterally closed lattice structures are appropriate candidates to be implemented in a new generation of implants. Full article
(This article belongs to the Special Issue Advanced Manufacturing and Nondestructive Testing Techniques)
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