Additive manufacturing processes produce components that may introduce material anomalies at any location within a component. NDE inspection can be used to find and remove anomalies that could grow to failure during the service life, but two key inputs are required for an effective inspection: (1) the critical locations to search for anomalies, and (2) the minimum sizes of the anomalies that must be found. A new methodology is presented for probabilistic damage tolerance assessment of additively manufactured components. It consists of a new link between the DARWIN® probabilistic damage tolerance software and the XRSim X-ray NDE simulation software. DARWIN computes fracture risk and critical initial crack sizes throughout a component, providing the two key inputs that are necessary for effective NDE inspections. XRSim computes location-specific POD curves everywhere in a component, providing the key information needed to assess the influence of inspection on fracture risk reduction. The methodology is illustrated for a representative gas turbine engine component manufactured via the direct metal laser sintering process. The results can be used to optimize the effectiveness of NDE inspection of additively manufactured components.
Influences of Non-Destructive Inspection Simulation on Fracture Risk Assessment of Additively Manufactured Turbine Engine Components
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Enright, MP, McClung, RC, Sobotka, JC, Moody, JP, McFarland, J, Lee, Y, Gray, I, & Gray, J. "Influences of Non-Destructive Inspection Simulation on Fracture Risk Assessment of Additively Manufactured Turbine Engine Components." Proceedings of the ASME Turbo Expo 2018: Turbomachinery Technical Conference and Exposition. Volume 7A: Structures and Dynamics. Oslo, Norway. June 11–15, 2018. V07AT32A013. ASME. https://doi.org/10.1115/GT2018-77058
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