Defect Free Additive Manufacturing of Aerospace Superalloy Parts – Quality and Process Monitoring

Important results from the project

A sub-goal has been new international collaboration. This has involved collaboration between the project partners and the research institute BAM in Berlin. In addition, dialogue has been developed with Nikon SLM Solutions for future EU initiatives. A sub-goal has also been steps regarding in-situ quality assurance in AM processing. Here, we have done comparative manufacturing studies at Chalmers and BAM with state-of-the-art in-line technology (optical tomography) and developed new strategies.

Expected long term effects

Additive manufacturing is stong in Sweden. Powder bed fusion - laser beam is most mature in terms of industrialization and technology with good resulting properties and nominally full density. For serial production, advanced process monitoring is a key to quality assurance. The project has contributed to knowledge in this area. For the aerospace industry, AM strengthens resilience and improves fly-to-buy ratio. AI-controll of process monitoring can bring next step in development.

Approach and implementation

Designed builds were made with PBF-LB at Chalmers with Ni-alloy and 316L.stainless. Processing was done to create different sample quality across same build. In-situ monitoring was done with optical tomography (OT) with fixed IR wavelength. Samples were characterized and porosity was measured with XCT at GKN. Selected samples went to HIP at Quintus and then XCT again. BAM did PBF-LB for stainless steel with multiple IR in-situ OT, showing increased information and potential for new technology.