Metal additive manufacturing process control verification using advanced synchrotron tomography

This experiment aims to utilise the new scout and zoom capabilities offered on BM18 to conduct tomography experiments on full-scale additively manufactured (AM) components. In particular, we aim to map the defect distribution in turbine blade components manufactured using laser powder bed fusion from Ti-6Al-4V and Inconel 718 alloys to understand the efficacy of manufacturing process control algorithms in controlling defect structures in real components. Until now we have had to study defects introduced by AM on sub-scale test-pieces rather than industrial-scale components. This will enable us to refine and validate control algorithms in manufacturing “on demand” full scale components and thereby to engineer the defect distribution to facilitate the uptake of AM for safety critical parts in industry.