Anomaly detection by X-ray tomography and probabilistic fatigue assessment of aluminum brackets manufactured by PBF-LB

L. Rusnati, M. Yosifov, S. Senck, R. Hubmann, S. Beretta

Research output: Contribution to journalArticlepeer-review

Abstract

The assessment of safety-critical components for fatigue applications is a key requirement for metal additive manufacturing (AM) applications. Material anomalies play a relevant role in determining the fatigue resistance properties of a component. X-ray computed tomography (CT) helps collect important information on these flaws, such as their size and position within a part. In this study, we discuss how to employ anomaly data detected on an AlSi10Mg bracket manufactured by laser-powder bed fusion to describe the prospective allowable life of a component under a given operating condition. A statistical analysis was conducted on the specimens and component to derive the correlation between different resolution scans and analyze the uncertainties of the micro-CT measurements. The full-scale non-destructive evaluation (NDE) can be constrained to large voxel sizes. Eventually, the authors proposed a fully probabilistic route for assessment instead of a simple deterministic assessment based on safety factors. This assessment enables designers to consider the uncertainties of the assessment (uncertainties of micro-CT detection and the model for fatigue strength).

Translated title of the contributionErkennung von Anomalien mittels Röntgen-Comptertomographie und probabilistische Ermüdungsbewertung von additiv-gefertigten Aluminium-Bauteilen
Original languageEnglish
Article number113467
Pages (from-to)1-14
Number of pages14
JournalMaterials and Design
Volume248
DOIs
Publication statusPublished - 19 Nov 2024

Keywords

  • Additive manufacturing
  • AlSi10Mg
  • Fatigue assessment
  • Probability of detection
  • Sizing error
  • X-ray computed tomography

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