Defect Considerations in Additively Manufactured Metal Components

Additively manufactured (3-D printed) metallic components are becoming more common in the aerospace industry. Specifically, components produced from powder bed fusion (PBF) and directed energy deposition (DED) processes are of great interest for creating individual or small batch replacement components. However, before authorizing a component for flight, a scientist or engineer must assess the potential failure modes of an in service component that may be unique to the additive manufacturing process. This presentation will distinguish between flaws related to build failures versus those defects that may be endemic to the process and explore the ramifications of these defects.