Process Refinement to Improve NDI in Additively Manufactured Components

This presentation will cover work perform to improve ultrasonic inspectability of components produced using the Electron Beam, Direct Manufacturing (EBDM) additive manufacturing process. EBDM is being qualified for F-35 Ti-64 titanium components. The qualification has been hampered by limited methods to inspect the components. Traditional radiographic methods could not reliably detect crack like flaws if apparent radiographic section sizes exceed 3 inches. Ultrasonic methods have traditionally been used for wrought materials but have limited usefulness with EBDM because of non-isotropic microstructure that develops during deposition and grows during subsequent heat treatment. The microstructure consists of alternating bands of columnar and equiaxed grains that attenuate ultrasonic signals differently. This presentation will review the issue and discuss process refinements evaluated to refine the microstructure specifically to improve ultrasonic inspectability.