Comparative Evaluation of Crack-like Defects in Additively Manufactured Parts (AM Flaw)

As we explore the effectiveness of different Non-Destructive Evaluation (NDE) methods for Additively Manufactured (AM) parts, such as radiography, ultrasound, dye penetrant, etc., a few more fundamental questions have not been clearly answered. Broadly speaking, we do not understand if a crack in an AM part imparts a different NDE response than one in a traditional part. For this study, we aim to understand the difference in NDE response between AM and conventional manufactured parts. In particular, we aim to assess the NDE response as a function of surface topology (roughness/form differences, build orientation, etc.) and also as a function of internal grain structure.

Additive coupons will make use of industry standard 3D printing approaches and using materials relevant to NASA missions. Natural flaws will be induced in coupons using high cycle fatigue, in particular surface breaking cracks. Parallel sets of coupons will be made for each aspect of the study, i.e. a set to understand surface roughness and one for grain structure.