ADDITIVE MANUFACTURING PROJECT CLUSTER MEETING Non-destructive Testing of LBM and AM Fundació CIM C/Llorens i Artigas, 12 Parc Tecnològic de Barcelona Barcelona, Spain 2 May 2016 Mr. Hardus Greyling, CSIR National Laser Centre Pretoria South Africa

Non-destructive Testing of LBM and AM NDT on AM not always straight forward Europe looking under the Interpret-project at Eddy Current Testing Laser Ultrasonic Testing Infrared Thermography In Austria Plasmo Industrietechnik GmbH offers an integrated system which utilizes in- line Visual Testing, Infrared Thermographic Testing and Ultraviolet Radiation monitoring as a commercial system. At the CSIR looking at the following The utilization of the Total Focusing Method (TFM) – a development in the Phased Array Ultrasonic Testing field – for the inspection of LBM and AM components

Non-destructive Testing of LBM and AM What is TFM? It is also known as Full Matrix Capture (FMC) The phased array probe is steered in such fashion that the energy is focused at every point under the probe The algorithm has been expanded to allow scanning with probe in the TFM mode This makes the technique very powerful Can find discontinuities of around 100 µm Technique has been found to perform well

Exploitable results ER 1 Process: The use of the TFM for the scanning of AM processes such as: cladding and weld build up in situ. Thin wall welding

ER 1 - Process: The use of the TFM in AM TFM / FMC will make the inspection of repair work on large samples possible No need to perform Computed Tomography of cut-off pieces Much faster results available to affect repairs where necessary Potential customers All AM and LBM companies implementing AM as a manufacturing technology Customer Benefits Tested / inspected repair work using a demonstrated technology Reliable and repeatable application of AM and LBM

ER 1 - Process: The use of the TFM in AM Technological Readiness Level TLR 9 by 07/2018 Milestones in the TRL progression up to TRL9 Manufacturing of samples to demonstrate the TFM technology Performance of open trials to qualify the equipment and the inspection procedure Refinement of the inspection procedures and possible acquisition of better probes Compilation and qualification of NDT procedures including HCD Performance of blind trials to qualify NDT personnel System and procedures applied in the field (in situ) Main technical challenges in this result Manufacture of representative samples Time Time to market (Mth/yr): 1 year 6 months

Expressions of Interest (metal AM) M2-US-EXOVA ER1 - Design allowable database (M) ER 2 - Standard test & qualification protocols (H) M3-US-NIU ER 1 - Calorimeter to monitor heat input (M) ER 2 - Acoustic monitoring of powder flow (M) M4-SA-DEDREF ER1 - DED procedures for repair (H) ER2 - Image processing (H) ER3 - Minimising residual stresses in DMD (M) M5-SA-Forming ER1 - Hot sheet forming tool (L) ER2 - Reconfigurable tool (L) ER3 - Improved scanning (L) M6-SA-MEDAREA ER2 - Post processing of Ti6Al4V(L) ER3 - Process chains for Ti6Al4V products (H) M7-MX-FRISAER1 - Al powder (M) ER1 - Characterization of superalloy wires (L) ER2 - Cladding and repair of forge tool (L) ER3 - Adding features to forges (L) M9-EU-AMAZE ER1 - Defect-free metallic components (H) ER2 - Modular streamlined factory work-flow (H) ER3 - Adaptronics,novel sensing and process(H) M11-EU-RepAIR ER1 - Technologies for repairing (H) ER3 - Quality Component (H) M12-EU-BOREALIS ER1 - Borealis Machine: Large machine inline loop control(L) ER2 - Borealis Laser Head (H) ER3 - Borealis Process Monitoring Infrastructure (H) M13-EU-AATID ER1 - Optimal processes for Ti printed parts

Expressions of Interest (others) GT2-SA-EDUCATE ER1 - Knowledge/educational products (H) ER 2 - Training curricula (H) GT10-EU-CAXMAN ER1- Cloud Portal for Additive Manufacturing (L) ER2 - Algorithmic toolkits for Additive Manufacturing (L) ER3 - ISO (STEP) Part 242, ISO/ASTM52915 (L) GT12-EU-MANSYS ER1 - Outline quality system (M) ER2 - AM knowledge database (M) ER3 - BCT's software package OpenARMS (M)