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Additive manufacturing and non-destructive testing of topology-optimised aluminium components
Published in Nondestructive Testing and Evaluation, 2020
Sascha Senck, Michael Happl, Michael Reiter, Michael Scheerer, Manuel Kendel, Jonathan Glinz, Johann Kastner
This contribution used freely available CAD data of a real aerospace component that was optimised for weight reduction in order to investigate the microstructure of an actual AlSi10 Mg part produced by SLM. To ensure optimal image quality for the scan of the complete part, we used two different XCT simulation approaches to determine the part´s optimal scanning orientation and scanning parameters at a voxel size of 105 µm. Subsequently, we firstly extracted a safety critical region a clevis arm of one bracket that represents the region where the external force is applied and is thus subjected to high-stress levels during mechanical loading. Secondly, we cut-out of the component a smaller region (318.75 mm3) from the clevis arm for high-resolution scans. Parts of the cut-out were scanned at increasing higher physical resolutions (voxel sizes: 65, 20, 10 and 5 µm). Additionally, we investigated in-process samples at corresponding voxel sizes down to 1.25 µm to identify (micro-) pores that cannot be detected at a low physical resolution. To visualise the influence of voxel size on the detectability of pores, we computed pore size distributions for an in-process sample.