TY - CONF A1 - Léonard, Fabien A1 - Stein, J. T1 - Use of distance transforms and correlation maps for advanced 3D analysis of impact damage in composite panels T2 - 2nd International Conference on Tomography of Materials and Structures CY - Quebec, Canada DA - 2015-06-29 PY - 2015 AN - OPUS4-34600 LA - deu AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - JOUR A1 - Müller, Bernd R. A1 - Léonard, Fabien A1 - Lange, Axel A1 - Kupsch, Andreas A1 - Bruno, Giovanni T1 - X-ray refraction techniques for fast, high-resolution microstructure characterization and non-destructive testing of lightweight composites N2 - X-ray refraction is based on optical deflection of X-rays, similar to the well-known small angle X-ray scattering, but hundreds of times more intense, thus enabling shorter measurement time. We show that X-ray refraction techniques are suitable for the detection of pores, cracks, and in general defects. Indeed, the deflected X-ray intensity is directly proportional to the internal specific surface (i.e., surface per unit volume) of the objects. Although single defects cannot be imaged, the presence of populations of those defects can be detected even if the defects have sizes in the nanometer range.We present several applications of X-ray refraction techniques to composite materials:- To visualize macro and microcracks in Ti-SiC metal matrix composites (MMC);- To correlate fatigue damage (fibre de-bonding) of carbon fibre reinforced plastics (CFRP) to X-ray refraction intensity;- To quantify the impact damage by spatially resolved single fibre de-bonding fraction as a function of impact energy in CFRP laminates.An example of classic high-resolution computer tomography of an impact-damaged CFRP will also be presented, as a benchmark to the present state-of-the-art imaging capabilities. It will be shown that while (absorption) tomography can well visualize and quantify delamination, X-ray refraction techniques directly yield (spatially resolved) quantitative information about fibre de-bonding, inaccessible to absorption tomography. KW - X-ray KW - Synchrotron radiation KW - Refraction KW - Metal matrix composites KW - Delamination KW - Fiber de-bonding PY - 2015 U6 - https://doi.org/10.4028/www.scientific.net/MSF.825-826.814 SN - 0255-5476 VL - 825-826 SP - 814 EP - 821 PB - Trans Tech Publications CY - Aedermannsdorf, Switzerland AN - OPUS4-33265 LA - eng AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - JOUR A1 - Hernández-Nava, E. A1 - Smith, C.J. A1 - Derguti, F. A1 - Tammas-Williams, S. A1 - Léonard, Fabien A1 - Withers, P. J. A1 - Todd, I. A1 - Goodall, R. T1 - The effect of density and feature size on mechanical properties of isostructural metallic foams produced by additive manufacturing N2 - Simple models describing the relationship between basic mechanical properties and the relative density of various types of porous metals (such as foams, sponges and lattice structures) are well established. Carefully evaluating these relationships experimentally is challenging, however, because of the stochastic structure of foams and the fact that it is difficult to systematically isolate density changes from variations in other factors, such as pore size and pore distribution. Here a new method for producing systematic sets of stochastic foams is employed based on electron beam melting (EBM) additive manufacturing (AM). To create idealised structures, structural blueprints were reverse-engineered by inverting X-ray computed tomographs of a randomly packed bed of glass beads. This three-dimensional structure was then modified by computer to create five foams of different relative density ρr, but otherwise consistent structure. Yield strength and Young’s modulus have been evaluated in compression tests and compared to existing models for foams. A power of 3 rather than a squared dependence of stiffness on relative density is found, which agrees with a recent model derived for replicated foams. A similar power of 3 relation was found for yield strength. Further analysis of the strength of nominally fully dense rods of different diameters built by EBM AM suggest that surface defects mean that the minimum size of features that can be created by EBM with similar strengths to machined samples is ∼1 mm. KW - Metal foam KW - Cellular solids KW - Reverse engineering KW - Open-cell foam KW - X-ray computed tomography PY - 2015 U6 - https://doi.org/10.1016/j.actamat.2014.10.058 SN - 1359-6462 VL - 85 SP - 387 EP - 395 AN - OPUS4-39071 LA - eng AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - JOUR A1 - Tammas-Williams, S. A1 - Zhao, H. A1 - Léonard, Fabien A1 - Derguti, F. A1 - Todd, I. A1 - Prangnell, P.B. T1 - XCT analysis of the influence of melt strategies on defect population in Ti-6Al-4V components manufactured by Selective Electron Beam Melting N2 - Selective Electron Beam Melting (SEBM) is a promising powder bed Additive Manufacturing technique for near-net-shape manufacture of high-value titanium components. However without post-manufacture HIPing the fatigue life of SEBM parts is currently dominated by the presence of porosity. In this study, the size, volume fraction, and spatial distribution of the pores in model samples have been characterised in 3D, using X-ray Computed Tomography, and correlated to the process variables. The average volume fraction of the pores (b0.2%) was measured to be lower than that usually observed in competing processes, such as selective laser melting, but a strong relationship was found with the differentbeamstrategies used to contour ,and infill by hatching, a part section. The majority of pores were found to be small spherical gas pores, concentrated in the infill hatched region; this was attributed to the lower energy density and less focused beam used in the infill strategy allowing less opportunity for gas bubbles to escape the melt pool. Overall, increasing the energy density or focus of the beam was found to correlate strongly to a reduction in the level of gas porosity. Rarer irregular shaped pores were mostly located in the contour region and have been attributed to a lack of fusion between powder particles. KW - Titanium KW - Additive Manufacture KW - Selective Electron Beam Melting KW - Pores KW - X-ray computed tomography PY - 2015 U6 - http://nbn-resolving.de/urn/resolver.pl?urn:nbn:de:kobv:b43-416577 UR - http://www.sciencedirect.com/science/article/pii/S104458031500039X?via%3Dihub VL - 102 SP - 47 EP - 61 CY - Materials Characterization AN - OPUS4-41657 LA - eng AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - JOUR A1 - Hernández-Nava, E. A1 - Smith, C.J. A1 - Derguti, F. A1 - Tammas-Williams, S. A1 - Léonard, Fabien A1 - Withers, P. J. A1 - Todd, I. A1 - Goodall, R. T1 - The effect of defects on the mechanical response of Ti-6Al-4V cubic lattice structures fabricated by electron beam melting N2 - Electron Beam Melting (EBM) as a means of Additive Manufacturing (AM), is of interest for the fabrication of intricate geometries for cellular materials in areas where complex architectures are needed, e.g. biomedical implants. Most studies have focused on specific geometries and so the effect of the structure on mechanical performance is not well understood. Many kinds of micro- and macro-scale defects can arise in additively manufactured components, so assessment of their influence on properties is needed. In this work, lattices of Ti-6Al-4V having a cubic structure have been manufactured by EBM, and the effect of heat treatments above and below the β-transus temperature on microstructure and compression response have been investigated. The former modifies only slightly the α + β structure and mechanical performance whereas the latter leads to coarse alternating α and β lamellae packets and α at the prior grain boundaries with a 10% loss in yield strength. The variation in the compressive yield stress with strut diameter is in good accord with simple models based on compressive deformation rather than shearing or buckling. Internal pores for struts aligned with the build direction are found around the edges of the solid form, in regions which seem to be associated with the EB scan pattern. Struts normal to the build direction show more significant defects but their redundancy means that they do not compromise the compressive performance in the build direction. Using a particle size in the range 45–100 μm minimum weld-track sizes were experimentally and numerically identified to be 176 and 148 μm in depth respectively with a depth-to-width ratio of 0.55. This produced a beam pass of the order of 300 μm oversizing small features (struts of 0.4 and 0.6 mm nominal diameter) when a contour around the strut periphery was applied. KW - Cellular solids KW - Additive manufacturing KW - Titanium alloy KW - Mechanical properties KW - X-ray computed tomography PY - 2016 U6 - http://nbn-resolving.de/urn/resolver.pl?urn:nbn:de:kobv:b43-390686 SN - 1359-6454 VL - 108 SP - 279 EP - 292 PB - Elsevier Ltd. CY - Amsterdam [u.a.] AN - OPUS4-39068 LA - eng AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - CONF A1 - Léonard, Fabien A1 - Tammas-Williams, S. A1 - Todd, I. T1 - CT for additive manufacturing process characterisation: assessment of melt strategies on defect population N2 - Selective Electron Beam Melting (SEBM) is a promising powder bed Additive Manufacturing (AM) technique for near net-shape manufacturing of high-value titanium components. However, as with every emerging technique, the manufacturing processes can still be greatly improved and optimised. In particular, the links between AM settings and the resulting sample porosity is of great interest, as the fatigue life of SEBM parts is currently dominated by the presence of porosity. In this study, the size, volume fraction, and spatial distribution of the pores in model samples have been characterised in 3D, using X-ray Computed Tomography (CT), and correlated to the SEBM process variables. A strong relationship was found with the different beam strategies used to contour, and infill by hatching, a part section. The majority of pores were found to be small spherical gas pores, concentrated in the infill hatched region. Rarer irregular shaped pores were mostly located in the contour region and have been attributed to a lack of fusion between powder particles. T2 - Conference on Industrial Computed Tomography iCT2016 CY - Wels, Austria DA - 09.02.2016 KW - Titanium KW - Additive Manufacture KW - Selective Electron Beam Melting KW - Pores KW - Defects KW - X-ray Computed Tomography PY - 2016 AN - OPUS4-39186 LA - eng AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - CONF A1 - Léonard, Fabien A1 - Bruno, Giovanni T1 - Evaluating porosity in cordierite diesel particulate filter materials: advanced X-ray and new statistical analysis methods N2 - Complex materials (e.g., porous ceramics) need high resolution techniques at multi-scale levels. Microstructure is intimately linked to properties and performance. One technique (or even a few techniques) is not enough. X-ray refraction and CT are very powerful tools. Non-destructive characterisation and quantitative image analysis techniques (2D and 3D) are necessary to understand the anisotropy. T2 - 40th International Conference and Expo on Advanced Ceramics and Composites ( ICACC) CY - Daytona Beach, USA DA - 24.01.2016 KW - X-ray computed tomography KW - X-ray refraction KW - Directional interface variance analysis (DIVA) KW - FFT periodogram PY - 2016 AN - OPUS4-41725 LA - eng AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - CONF A1 - Léonard, Fabien A1 - Hasenfelder, Uta A1 - Krebs, Holger A1 - Bruno, Giovanni T1 - Synchrotron X-ray computed tomography for assessment of shock tube systems N2 - Shock tube systems are non-electric explosive fuses employed in blasting and demolition applications to trigger the detonation of explosive charges. Their working principle is based on the explosive reaction of a fine powder on the tubing´s inner surface, generating a percussive wave travelling at a velocity of 2,100 m/s along the length of the tube, without destroying it. One of the key aspects of the manufacturing process of these shock tubes is the size and morphology of the explosive powder grains and their distribution on the inner wall of the tube, in order to propagate the shockwave efficiently and reliably. For the first time, synchrotron X-ray computed tomography has been used to characterize non-destructively the explosive powder grains, typically Al/HMX between 10 and 20 μm in size, in terms of morphology and 3D distribution but also to characterise the presence and location of defects within the shock tube walls. T2 - 7th Conference on Industrial Computed Tomography CY - Leuven, Belgium DA - 07.02.2017 KW - Explosive KW - Nonel KW - Shock wave KW - Blasting KW - Energetic systems PY - 2017 AN - OPUS4-39168 LA - eng AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - JOUR A1 - Lüchtenborg, Jörg A1 - Mühler, T. A1 - Léonard, Fabien A1 - Günster, Jens T1 - Laser-induced slip casting (LIS) – a new additive manufacturing process for dense ceramics demonstrated with Si3N4 N2 - Up to now, there exists a lack of methods for the additive manufacturing of voluminous ceramic parts with properties comparable to those of conventionally manufactured ones. A high density after sintering is needed to reach the superior properties of ceramic materials. We have developed a new additive manufacturing method, Laser-Induced Slip casting (LIS), to generate ceramic green bodies with high particle packing density and with virtually no restriction in the particle size of the feedstock, especially in terms of small particles. This is achieved by laser-induced local drying of slurries, with the process resembling many features of the well-established stereolithography, but without the excessive use of polymeric material. Thus, unlike the stereolithography process, the resulting green bodies can be processed like traditionally produced ceramic parts. This method allows large and dense additive-manufactured parts to be obtained from conventional water-based ceramic slurries. As an example, we will demonstrate the application of this novel technique with Si3N4. KW - Additive manufacturing KW - Ceramics PY - 2017 U6 - https://doi.org/10.4416/JCST2017-00091 SN - 2190-9385 VL - 8 IS - 4 SP - 531 EP - 540 PB - Göller Verlag CY - Baden-Baden AN - OPUS4-43738 LA - eng AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - CONF A1 - Léonard, Fabien A1 - Hasenfelder, Uta A1 - Krebs, Holger A1 - Bruno, Giovanni T1 - Assessment of shock tube systems by synchrotron X-ray computed tomography N2 - Shock tube systems are non-electric explosive fuses employed in blasting and demolition applications to trigger the detonation of explosive charges. Their working principle is based on the explosive reaction of a fine explosive powder on the tubing's inner surface, generating a shock wave traveling at a velocity of 2,100 m/s along the length of the tube, without destroying it. One of the key aspects of the manufacturing process of these shock tubes is the size and morphology of the explosive powder grains and their distribution on the inner wall of the tube, in order to propagate the shockwave efficiently and reliably. For the first time, synchrotron X-ray computed tomography has been used to characterize non-destructively the explosive powder grains, typically Al/HMX between 10 and 20 μm in size, in terms of morphology and 3D distribution but also to characterise the presence and location of defects within the shock tube walls. KW - Explosives KW - Nonel KW - Shock wave KW - Blasting KW - Energetic systems PY - 2017 UR - http://www.ndt.net/events/iCT2017/app/content/Paper/61_Leonard.pdf SP - 1 EP - 7 CY - Leuven, Belgium AN - OPUS4-39345 LA - eng AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER -