Quality assurance for additively manufactured components

Additively manufactured components are increasingly finding their way into industrial production. Especially in lightweight construction, additive processes are resource-saving alternatives. However, there is a lack of studies and binding regulations on the quality assurance of additively manufactured parts.

In the QuaPla research project, ifw Jena was already investigating the effects of different types of defects on the strength and durability of additively manufactured parts. Samples were manufactured using the powder bed process and defects of different types and sizes were deliberately introduced. Subsequently, the samples were statically drawn in the materials testing laboratory and their strength was investigated. The test results from QuaPla have already made it possible to develop an initial approach for a generally applicable set of rules for the quality assurance of additively manufactured parts.

In the follow-up project EDaB – Influence on the fatigue strength of additive components – the tests are now being extended to the dynamic strength of the specimens. Additively manufactured specimens with introduced defects are subjected to vibrations in our dynamic tension/compression test system until failure. Number of vibration cycles, until sample destruction shows the effects of pores, cracks or surface defects of different sizes on additively manufactured parts.

The results should provide further insight into the extent to which defects can be tolerated in the additive manufacturing process. The investigations will provide characteristic values that will enable binding standards for quality assurance on additively manufactured components.

The project is funded by the German Federal Ministry for Economic Affairs and Energy in the INNO-KOM program.

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