The challenges in edge detection and porosity analysis for dissimilar materials additive manufactured components

Ahmed Tawfik, Radu Racasan, Desi Bacheva, Liam Blunt, Paul Bills

Research output: Chapter in Book/Report/Conference proceedingConference contribution

Abstract

AM is being recognized as a core technology for producing complex and customized components. Several AM machines can manufacture components using dissimilar materials which provides a substantial advantage by combining the mechanical properties of several materials in a single component. However, there are several challenges stopping the industry from widely utilizing AM in critical components. The mechanical properties of AM components are not well understood, furthermore nondestructive testing (NDT) and repeatability are not well established. X-ray computed tomography (XCT) is one of the most promising NDT methods that can detect porosity/defects and provide information regarding the position, location distribution and volume of any pores/defects. This paper presents a case study that highlights the challenges in edge detection and porosity analysis for AM manufactured components using dissimilar metallic materials. The artefact used in this experiment consists of two individual components built using Aluminium and Titanium powders that are then assembled together. The two components contain machined defect filled with unfused Titanium powder which prior to assembly were characterised using a focus variation microscope (Alicona G4) in order to determine the reference values for the diameter and depth of each defect. A Nikon XTH225 (Nikon Metrology, Tring) industrial XCT was used to analyse the pores/ defects’ location and size. The XCT data was reconstructed and the analysis for surface determination and defect analysis was carried out using VG Studio Max 3.1 (Volume Graphics, Heidelberg). The emphasis of the study is providing guidelines for selecting the inspection parameters, optimizing the surface determination to allow for porosity analysis and edge detection in dissimilar materials components built using in AM powder bed fusion (PBF).

LanguageEnglish
Title of host publicationEuropean Society for Precision Engineering and Nanotechnology, Conference Proceedings - 19th International Conference and Exhibition, EUSPEN 2019
EditorsC. Nisbet, Richard K. Leach, D. Billington, D. Phillips
Publishereuspen
Pages350-351
Number of pages2
ISBN (Electronic)9780995775145
Publication statusPublished - 2019
Event19th International Conference of the European Society for Precision Engineering and Nanotechnology - Euskalduna, Bilbao, Spain
Duration: 3 Jun 20197 Jun 2019
Conference number: 19
https://www.euspen.eu/events/19th-ice-bilbao/

Conference

Conference19th International Conference of the European Society for Precision Engineering and Nanotechnology
Abbreviated titleEUSPEN 2019
CountrySpain
CityBilbao
Period3/06/197/06/19
Internet address

Fingerprint

Dissimilar materials
edge detection
Edge detection
Porosity
porosity
Defects
Powders
Tomography
defects
Titanium
Nondestructive examination
X rays
tomography
Mechanical properties
Studios
titanium
Aluminum
mechanical properties
Microscopes
x rays

Cite this

Tawfik, A., Racasan, R., Bacheva, D., Blunt, L., & Bills, P. (2019). The challenges in edge detection and porosity analysis for dissimilar materials additive manufactured components. In C. Nisbet, R. K. Leach, D. Billington, & D. Phillips (Eds.), European Society for Precision Engineering and Nanotechnology, Conference Proceedings - 19th International Conference and Exhibition, EUSPEN 2019 (pp. 350-351). euspen.
Tawfik, Ahmed ; Racasan, Radu ; Bacheva, Desi ; Blunt, Liam ; Bills, Paul. / The challenges in edge detection and porosity analysis for dissimilar materials additive manufactured components. European Society for Precision Engineering and Nanotechnology, Conference Proceedings - 19th International Conference and Exhibition, EUSPEN 2019. editor / C. Nisbet ; Richard K. Leach ; D. Billington ; D. Phillips. euspen, 2019. pp. 350-351
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Tawfik, A, Racasan, R, Bacheva, D, Blunt, L & Bills, P 2019, The challenges in edge detection and porosity analysis for dissimilar materials additive manufactured components. in C Nisbet, RK Leach, D Billington & D Phillips (eds), European Society for Precision Engineering and Nanotechnology, Conference Proceedings - 19th International Conference and Exhibition, EUSPEN 2019. euspen, pp. 350-351, 19th International Conference of the European Society for Precision Engineering and Nanotechnology, Bilbao, Spain, 3/06/19.

The challenges in edge detection and porosity analysis for dissimilar materials additive manufactured components. / Tawfik, Ahmed; Racasan, Radu; Bacheva, Desi; Blunt, Liam; Bills, Paul.

European Society for Precision Engineering and Nanotechnology, Conference Proceedings - 19th International Conference and Exhibition, EUSPEN 2019. ed. / C. Nisbet; Richard K. Leach; D. Billington; D. Phillips. euspen, 2019. p. 350-351.

Research output: Chapter in Book/Report/Conference proceedingConference contribution

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T1 - The challenges in edge detection and porosity analysis for dissimilar materials additive manufactured components

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N2 - AM is being recognized as a core technology for producing complex and customized components. Several AM machines can manufacture components using dissimilar materials which provides a substantial advantage by combining the mechanical properties of several materials in a single component. However, there are several challenges stopping the industry from widely utilizing AM in critical components. The mechanical properties of AM components are not well understood, furthermore nondestructive testing (NDT) and repeatability are not well established. X-ray computed tomography (XCT) is one of the most promising NDT methods that can detect porosity/defects and provide information regarding the position, location distribution and volume of any pores/defects. This paper presents a case study that highlights the challenges in edge detection and porosity analysis for AM manufactured components using dissimilar metallic materials. The artefact used in this experiment consists of two individual components built using Aluminium and Titanium powders that are then assembled together. The two components contain machined defect filled with unfused Titanium powder which prior to assembly were characterised using a focus variation microscope (Alicona G4) in order to determine the reference values for the diameter and depth of each defect. A Nikon XTH225 (Nikon Metrology, Tring) industrial XCT was used to analyse the pores/ defects’ location and size. The XCT data was reconstructed and the analysis for surface determination and defect analysis was carried out using VG Studio Max 3.1 (Volume Graphics, Heidelberg). The emphasis of the study is providing guidelines for selecting the inspection parameters, optimizing the surface determination to allow for porosity analysis and edge detection in dissimilar materials components built using in AM powder bed fusion (PBF).

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KW - Additive manufacturing

KW - Dissimilar materials

KW - Edge Detection

KW - Non-destructive testing

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KW - Surface determination

KW - Unfused powder

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Tawfik A, Racasan R, Bacheva D, Blunt L, Bills P. The challenges in edge detection and porosity analysis for dissimilar materials additive manufactured components. In Nisbet C, Leach RK, Billington D, Phillips D, editors, European Society for Precision Engineering and Nanotechnology, Conference Proceedings - 19th International Conference and Exhibition, EUSPEN 2019. euspen. 2019. p. 350-351