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ASTM Selected Technical Papers
Structural Integrity of Additive Manufactured Materials and Parts
By
Nima Shamsaei
Nima Shamsaei
Symposium Chair and STP Editor
1
Auburn University
,
Auburn, AL,
US
Search for other works by this author on:
Mohsen Seifi
Mohsen Seifi
Symposium Chair and STP Editor
2
ASTM International
,
Washington, DC,
US
Search for other works by this author on:
ISBN:
978-0-8031-7708-6
No. of Pages:
378
Publisher:
ASTM International
Publication date:
2020

Nondestructive evaluation (NDE) has been used for materials and component manufacturing, typically for process quality control or at multiple steps in manufacturing processes. In addition, NDE is used in sustainment of aircraft components to detect defects with a validated capability quantified by probability of detection. U.S. Air Force (USAF) Structures Bulletin EZ-SB-19-01, “Durability and Damage Tolerance Certification for Additive Manufacturing of Aircraft Structural Metallic Parts,” emphasizes the use of NDE in manufacturing by defining five factors to be evaluated to specify a new material, process, joining method, and/or structural concepts. The factors include stability, producibility, characterization of mechanical or physical properties, predictability of structural performance, and supportability. Included is Section 3.4, “Nondestructive Inspection Development, Validation, Verification, and Implementation,” which provides instructions to determine the validated capability for all damage types, orientations, and locations for specific regions of interest. Factors that affect NDE capability include where in the manufacturing process the assessment occurs, the nature of the raw feedstock, and the diagnostic information required to ensure the quality of the produced part. Once manufactured, additional factors must be considered, including the nature/orientation of defects, access, surface condition, geometric complexity, internal microstructural characteristics, and potential residual stresses. Representative defects within additive manufactured (AM) parts/materials include micro-cracks, voids, delaminations, lack of fusion, porosity, and inclusions. Systematic approaches are needed that leverage existing methods for other manufacturing processes. Methods to assist in determining which NDE method(s) have the highest potential of success are discussed. However, the intent is not to provide an overview of all NDE methods and their applicability to assessing AM components. In addition, methods to simplify or accelerate the assessment of the probability of detection of the defect of interest are addressed. These items should provide insight into how to ensure AM parts can be qualified and sustained for aerospace applications.

1.
USAF
, “
Durability and Damage Tolerance Certification for Additive Manufacturing of Aircraft Structural Metallic Parts
,” EZ-SB-019-01 (
Wright Patterson AFB, OH
:
USAF
,
2019
).
2.
Department of Defense Standard Practice—Aircraft Structural Integrity Program (ASIP)
, MIL STD 1530Dc1 (
Washington, DC
:
U.S. Department of Defense
,
2016
).
3.
Department of Defense Standard Practice—Propulsion System Integrity Program (PSIP)
, MIL STD 3024 (
Washington, DC
:
U.S. Department of Defense
,
2008
).
4.
Naguy
D.
,
“Leveraging Additive Manufacturing to Enhance Mission Generation
,” in
Proceedings of the 2018 Additive Manufacturing for Maintenance Operations Workshop
, ed.
Hurt
P.
(
Ann Arbor, MI
:
Department of Defense Additive Manufacturing for Maintenance Operations
,
2018
).
5.
Threats to Aircraft Structural Safety, Including a Compendium of Selected Structural Accidents/Incidents
, ASC-TR-2010-5002 (
Wright Patterson AFB, OH
:
USAF Aeronautical Systems Center
,
2010
).
6.
Shamsaei
N.
and
Seifi
M.
,
Structural Integrity of Additive Manufactured Materials and Parts
(
West Conshohocken, PA
:
ASTM International
,
2020
).
7.
Standard Terminology for Additive Manufacturing—General Principles—Terminology
, EN ISO/ASTM 52900 (
West Conshohocken, PA
:
ASTM International
, approved December 1,
2015
),
8.
U.S. Department of Defense
,
Nondestructive Evaluation System Reliability Assessment
, MIL HDBK 1823A (
Washington, DC
:
U.S. Department of Defense
,
2009
).
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