Additive manufacturing (AM) processes enable an increased amount of design freedom compared to conventional subtractive manufacturing. By creating a part in near net shape, an efficient use of resources is possible. The higher production efficiency has economic and ecological benefits, but the widespread adoption of AM is currently hindered by the high cost of production. The production costs are mainly driven by extensive efforts to provide reliable quality assurance, which is necessary due to scatter in production parameters. For further industry relevance, AM parts need appropriate fatigue resistance, comparable to conventionally produced parts. Fatigue failure nucleates primarily at surface defects or pores. While surface defects can be removed by proper surface finishing, pores remain inside the part. These pores serve as nucleation points for fatigue crack initiation. Different methods to evaluate the effect of these pore defects have been proposed. They differ in defect detection, modelling and simulation approaches. This paper gives an overview and comparison of those methods and describes potential solutions to alleviate the shortcomings of the chosen methods towards a holistic approach on fatigue handling.

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Optimising Fatigue Quality Assurance in Additive Manufacturing: A Review on Internal Defects and Surface Roughness

  • Sebastian Mansky,
  • Stefan Grottker,
  • Arthur Seibel,
  • Ingomar Kelbassa

摘要

Additive manufacturing (AM) processes enable an increased amount of design freedom compared to conventional subtractive manufacturing. By creating a part in near net shape, an efficient use of resources is possible. The higher production efficiency has economic and ecological benefits, but the widespread adoption of AM is currently hindered by the high cost of production. The production costs are mainly driven by extensive efforts to provide reliable quality assurance, which is necessary due to scatter in production parameters. For further industry relevance, AM parts need appropriate fatigue resistance, comparable to conventionally produced parts. Fatigue failure nucleates primarily at surface defects or pores. While surface defects can be removed by proper surface finishing, pores remain inside the part. These pores serve as nucleation points for fatigue crack initiation. Different methods to evaluate the effect of these pore defects have been proposed. They differ in defect detection, modelling and simulation approaches. This paper gives an overview and comparison of those methods and describes potential solutions to alleviate the shortcomings of the chosen methods towards a holistic approach on fatigue handling.