INTRAPID produces rapid in-line inspection systems for laser additive manufactured components
The work, using specially designed non-destructive testing techniques, has important implications for the aerospace and automotive sectors, for example, where validation of components made using additive manufacturing techniques has until now been difficult to achieve. The final demonstration of the new methods took place at TWI’s Technology Centre in Yorkshire in August 2013 and showed three systems in operation, attached in turn to the same robot carrying out the deposition. The project team was able to demonstrate successfully that inspection can follow the deposition process by means of a simple translation of robot movement. The team chose to use laser ultrasonics, laser thermography and eddy current testing techniques in its system designs because each of these has a small inspection footprint – necessary to inspect a thin deposited layer. The systems comprised newly built specialist equipment together with a software suite, which included the data acquisition, display and analysis. To determine inspection performance, the researchers produced a wide range of reference samples in different materials and of varied shape containing machined flaws. They also devised techniques to introduce known flaws in deposited layers of either Inconel 600 or a copper alloy on aluminium substrate. Subsequent testing of these samples enabled the team to produce performance data for each inspection method, as a graph comparing flaw size against its depth below surface. One of the systems is expected to be used first by the automotive industry in the production of a new generation of laser-additive-manufactured components. INTRAPID was co-ordinated in the UK by TWI, with project partners Bytest (Italy), Tecnitest (Spain), Polkom (Poland), LPW Technology (UK), Toyota (Belgium), Kingston Computer Consultancy (UK), UNIPA (Italy). The work was funded by the EC through the Research Executive Agency. For more information please contact Franco Baratta at Bytest (baratta@bytest.it) or visit the INTRAPID project website www.intrapid.eu Ends Notes to Editors The INTRAPID project is a collaboration between European SMEs and research organisations. Its aim has been to develop three non-destructive testing (NDT) techniques for inspection of parts and components manufactured by additive manufacturing processes, in particular laser metal deposition (LMD). LMD is a technology that has been maturing over the last 20 years and has found application in repair, coatings, hybrid build and 3D near net shape manufacture of small intricate parts that can be used in aero and automobile engines to improve efficiency. Currently this technology cannot be used to supply some of these parts because absence of flaws that might be left in the component during manufacture cannot be guaranteed. TWI TWI is one of the world’s foremost independent research and technology organisations, with expertise in solving problems in all aspects of manufacturing, fabrication and whole-life integrity management technologies. Established at Abington, Cambridge, UK in 1946 and with several facilities across the globe, the company has a first class reputation for service through its teams of internationally respected consultants, scientists, engineers and support staff, whose knowledge and expertise is available to its Members as and when they require. The company employs over 700 staff, serving 700 Member companies across 4500 sites in 80 countries. TWI also houses a professional institution, The Welding Institute, with a separate membership of 6000 individuals. TWI, Granta Park, Abington, Cambridge CB21 6AL. Tel: 01223 899000. Fax: 01223 892588. E-mail: twi@twi.co.uk. Web: www.twi.co.uk 67/13 23 October 2013 catherine.condie@twi.co.uk
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