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The quality of components made by laser beam melting (LBM) additive manufacturing is naturally influenced by the quality of the powder bed. A packing density <1 and porosity inside the powder particles lead to intrinsic voids in the powder bed. Since the packing density is determined by the particle size and shape distribution, the determination of these properties is of significant interest to assess the printing process. In this work, the size and shape distribution, the amount of the particle’s intrinsic porosity, as well as the packing density of micrometric powder used for LBM, have been investigated by means of synchrotron X-ray computed tomography (CT). Two different powder batches were investigated: Ti–6Al–4V produced by plasma atomization and stainless steel 316L produced by gas atomization. Plasma atomization particles were observed to be more spherical in terms of the mean anisotropy compared to particles produced by gas atomization. The two kinds of particles were comparable in size according to the equivalent diameter. The packing density was lower (i.e., the powder bed contained more voids in between particles) for the Ti–6Al–4V particles. The comparison of the tomographic results with laser diffraction, as another particle size measurement technique, proved to be in agreement.
The computer simulation of radiography is applicable for different purposes in NDT such as for the qualification of NDT systems, the optimization of system parameters, feasibility analysis, model-based data interpretation, education and training of NDT/NDE personnel, and others. Within the framework of the European project PICASSO simulators will be adapted to support reliability assessments of NDT tasks. The radiographic simulator aRTist developed by BAM is well suited for this task. It combines analytical modelling of the RT inspection process with the CAD-orientated object description applicable to various industrial sectors such as power generation, aerospace, railways and others. The analytic model includes the description of the radiation source, the interaction of Radiation
with the material of the part, and the detection process with special focus to DIR. To support reliability estimations the simulation tool is completed by a tool for probability of detection (POD) estimation. It consists of a user interface for planning automatic simulation runs with varying parameters, specifically defect variations.
Further, an automatic image analysis procedure is included to evaluate the defect visibility and calculate the POD therefrom.
X-ray computed tomography (CT) is a volumetric (3D) Imaging diagnostic method, well established in the medical field, and in industrial NDE as well. Developments in industrial CT aim to extent the applicability to complex structures, which do not allow the access of all directions. This are e.g. limited view, data and angle CT applications. New reconstruction algorithms are required on one
side, and the accuracy has to be improved on the other side. Numerical Simulation can support such developments by providing well defined data sets for the testing of reconstruction algorithms. This approach of virtual CT is realized within the radiographic simulator aRTist, developed by BAM. The poster shows the possibilities of this tool to consider complex scan paths. Simulated data sets have been reconstructed by an versatile backprojection algorithm.