GE T
Mission possible: The five-year plan to gain FAA and EASA acceptance of in-process monitoring 2
ASTM International Additive Manufacturing Center of Excellence
2
Figure 1 At the European Union Aviation Safety Agency (EASA) and Federal Aviation Key Topics for the In-Situ Technology Readiness Administration (FAA) summit in Cologne, Germany, this September, Don for Applications in AM Qualification and Certification Workshop. Godfrey, Nikon SLM Solutions, and Fernando Lartategui, ITP Aero, co-chaired a Working Group whose mission is of critical importance to the metal Additive AM processes are rapidly being industrialized, The use of these ISM systems for process qualification Manufacturing industry. What is that To charteffort a five-year path which with powder bed fusion (PBF) mission? and directed energy will require the ability to confidently detect (or deposition (DED) having the widest adoption for metal predict) type, size, and location of defects in a build, ends with in-situ monitoring by the have FAA/EASAwithasa known a method applications. ISMapproved and control technologies confidencefor levelpart nominally equivalent been developed for AM with the potential to detect to that of ex-situ inspection techniques (such as x-ray acceptance. Here, the chairs present an overview of the current landscape process instability and part quality in near real-time CT). Currently, the industry does not have a consensus to enable closed-loop control and reporting of in-situ framework for validation of sensors and analysis and consider the challenges on the path to this crucial goal. quality metrics to supplement ex-situ inspection for techniques. These developments also require very
Introduction
part certification. In the current state, ISM primarily provides qualitative quality metrics derived from deviations in process parameters (e.g., laser power) process measurements (e.g., melt pool irradiance) and part appearance (e.g., layer imaging). These systems have been adopted at some level as standard In response to industry interestimplementations with the pastmajor events having OEMs been by most AM machine and some are generally viewedin asCologne necessaryin for2019 the and the rapid expansion of Additive hosted by EASA operation of AM systems(e.g., track height monitoring Manufacturing (AM) use in the and feedback andcontrol virtually in 2021 and by FAA in in DED), but do not currently production of aviation parts, theprovide sufficient Wichita, Kansas, in of 2018 and virtually value in the form standardization to process manyThe of those systems[6]. European Aviation Safety Agencythe qualification in 2020 andfor 2022. presentations
(EASA) started offering workshops on the Qualification and Certification (Q&C) of AM in 2015. These workshops had a specific focus on promoting technical dialog and knowledge sharing between key stakeholder groups, including government agencies, industry, public standards organisations and academia. In the US, the Federal Aviation Administration (FAA) started offering workshops on the Q&C of AM as well in about the same timeframe. The first three FAA workshops were organised in partnership with the United States Air Force (USAF) and the Air Force Research Laboratory (AFRL). As part of this process, and in response to industry requests, the EASA and FAA have been increasingly working together, resulting in collaboration and alternate hosting of an annual joint aviation AM event,
Vol. 9 No. 4 © 2023 Inovar Communications Ltd
and outputs from these events are available in the public domain [1,2].
large experimental datasets that have spatially resolved ISM signals correlated to ex-situ inspection. To enable part- and process-agnostic ISM tools, collaboration across disciplines (e.g., data analysis, , materials, process, design, etc.) is needed to advance physicsinformed modeling and transfer learning.
The 2023 event was held in
This document summarizes the state-of-the-art of Cologne, from 19-21, and that ISM technology fromSeptember a 2020 landscape analysis it continued building on outcomes details sensor technologies andthe notable commercial and efforts (Appendix A). In addition to an inofresearch the recent successful workshops, depth literature review, twenty-one (21) interviews were
while striving to offer new coverage and technical insights based on the most recent developments in the area
Real-Time Detection/Closed-Loop Control Technical Development /Maturation
Standards
Data/Defect Correlation
In-Situ Technology Readiness
Detectable Flaw States
Fig. 1 Key topics for the In-Situ Technology Readiness for Applications in AM Qualification and Certification Workshop (Courtesy ASTM International)
Metal Additive Manufacturing | Winter 2023
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In-process monitoring for aviation
PD
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