Non-Destructive Inspection (NDI) of Electron Beam Direct Manufacturing (EBDM) of Titanium

Emerging additive manufacturing technologies such as electron beam direct manufacturing (EBDM) are considered vital to improve affordability and reduce lead times associated with traditional manufacturing technologies.  However, a major challenge associated with introducing additive manufactured components into the F-35 supply stream is development and acceptance of required non-destructive inspection (NDI) methodologies and standards to ensure the resulting product meets quality and design requirements.  A Navy Metalworking Center (NMC) project is evaluating the effectiveness of traditional and advanced NDI techniques (including traditional radiography, standard ultrasonic, phased array ultrasonic and dye penetrant test inspection methods) to establish standardized NDI processes and procedures for production of EBDM titanium components.  The project objectives are to a) quantify the capability of NDI methods to detect defects of types and sizes that may be present in EBDM-fabricated parts at various locations and orientations, and b) quantify the effects of surface finish and microstructure on detection capability.

This presentation will include results from two NMC project tasks.  The first is NDI and metallographic inspections of test coupons containing intentionally implanted defects.  The second is determining the flaw detection limits of NDI on EBDM test structures exhibiting different surface roughness conditions at various build thicknesses and evaluating the effects of a beta anneal heat treatment on inspectability.

This project is funded by the Industrial Base Innovation Fund and the Navy ManTech Program and is being executed by an Integrated Project Team (IPT) consisting of Lockheed Martin Aeronautics - Advanced Development Programs, Sciaky, Inc., Joint Strike Fighter Joint Program Office, Air Force Research Laboratory (AFRL), Naval Air Systems Command and NMC.

This abstract was prepared by the Navy Metalworking Center, operated by Concurrent Technologies Corporation, under Contract No. N00014-10-D-0062 to the Office of Naval Research as part of the Navy ManTech Program. Approved for public release; distribution is unlimited.