Skip to main content
SpringerLink
Log in

Study of laser metal deposition additive manufacturing, CNC milling, and NDT ultrasonic inspection of IN718 alloy preforms

  • ORIGINAL ARTICLE
  • Published:
The International Journal of Advanced Manufacturing Technology Aims and scope Submit manuscript

Abstract

In this work, a study of the complete value chain for 2.5D preforms manufacturing using laser metal deposition (LMD) was performed. Process development covers the optimization of LMD process parameters and different deposition strategies to generate near-net-shape preforms, including straight ribbed walls made of IN718 alloy. The influence of geometrical distortions, rigidity, and hardness of the obtained LMD preforms was analyzed. Additionally, CNC milling process was performed and analyzed, measuring the cutting forces and surface roughness, and estimating its influence of LMD as-built condition in the final machined component. Finally, a new methodology for automatic ultrasonic testing (UT) of LMD-powder additively manufactured preforms demonstrated the feasibility of detecting and locating surface and internal defectology with sizes between 25 and 200 microns in the studied samples.

This is a preview of subscription content, log in via an institution to check access.

Access this article

Log in via an institution

Price excludes VAT (USA)
Tax calculation will be finalised during checkout.

Instant access to the full article PDF.

Institutional subscriptions

Fig. 1
Fig. 2
Fig. 3
Fig. 4
Fig. 5
Fig. 6
Fig. 7
Fig. 8
Fig. 9
Fig. 10
Fig. 11
Fig. 12
Fig. 13
Fig. 14
Fig. 15
Fig. 16
Fig. 17
Fig. 18
Fig. 19
Fig. 20
Fig. 21
Fig. 22

Similar content being viewed by others

Availability of data and material

The raw/processed data required to reproduce these findings cannot be shared at this time due to technical or time limitations.

References

  1. Hosseini E, Popovich VA (2019) A review of mechanical properties of additively manufactured Inconel 718. Addit Manuf 30:100877. https://doi.org/10.1016/j.addma.2019.100877

  2. Ghiban B, Elefterie CF, Guragata C, Bran D (2018) Requirements of Inconel 718 alloy for aeronautical applications. AIP Conf Proc 1932:30016. https://doi.org/10.1063/1.5024166

    Article  Google Scholar 

  3. Godec M, Malej S, Feizpour D et al (2021) Hybrid additive manufacturing of Inconel 718 for future space applications. Mater Charact 172:110842. https://doi.org/10.1016/j.matchar.2020.110842

  4. AM-motion (2018) A strategic approach to increasing Europe´s value proposition foradditive manufacturing technologies and capabilities

  5. McCue T (2019) FORBES - significant 3D printing forecast surges to $35.6 billion. In Forbes Web. https://www.forbes.com/sites/tjmccue/2019/03/27/wohlers-report-2019-forecasts-35-6-billion-in-3d-printing-industry-growth-by-2024/. Accessed 25 Sep 2019

  6. Papadakis L (2021) Chapter 22 - Modeling and simulation of additive manufacturing processes with metallic powders—potentials and limitations demonstrated on application examples. In Pou J, Riveiro A, Davim JP (eds) Addit Manuf. Elsevier, pp 685–721

    Chapter  Google Scholar 

  7. International Organization for Standardization (2015) ISO/ASTM 52900:2015 Additive manufacturing — General principles — Terminology

  8. ASTM International (2016) ASTM F3187–16, Standard guide for directed energy deposition of metals

  9. Pinkerton AJ (2015) Advances in the modeling of laser direct metal deposition. J Laser Appl 27:S15001. https://doi.org/10.2351/1.4815992

    Article  Google Scholar 

  10. Calleja A, Tabernero I, Ealo JA et al (2014) Feed rate calculation algorithm for the homogeneous material deposition of blisk blades by 5-axis laser cladding. Int J Adv Manuf Technol 74:1219–1228. https://doi.org/10.1007/s00170-014-6057-3

    Article  Google Scholar 

  11. Cortina M, Arrizubieta JI, Ruiz JE et al (2018) Latest developments in industrial hybrid machine tools that combine additive and subtractive operations. Materials (Basel) 11. https://doi.org/10.3390/ma11122583

    Article  Google Scholar 

  12. Li L, Yan L, Zeng C, Liou F (2021) An efficient predictive modeling for simulating part-scale residual stress in laser metal deposition process. Int J Adv Manuf Technol 114:1819–1832. https://doi.org/10.1007/s00170-021-07005-6

    Article  Google Scholar 

  13. Heigel JC, Phan TQ, Fox JC, Gnaupel-Herold TH (2018) Experimental investigation of residual stress and its impact on machining in hybrid additive/subtractive manufacturing. Procedia Manuf 26:929–940. https://doi.org/10.1016/j.promfg.2018.07.120

  14. Calleja A, Urbikain G, González H et al (2018) Inconel®718 superalloy machinability evaluation after laser cladding additive manufacturing process. Int J Adv Manuf Technol 97:2873–2885. https://doi.org/10.1007/s00170-018-2169-5

    Article  Google Scholar 

  15. Gao M, Li L, Wang Q et al (2022) Integration of additive manufacturing in casting: advances, challenges, and prospects. Int J Precis Eng Manuf Technol 9:305–322. https://doi.org/10.1007/s40684-021-00323-w

    Article  Google Scholar 

  16. Thakur DG, Ramamoorthy B, Vijayaraghavan L (2009) Study on the machinability characteristics of superalloy Inconel 718 during high speed turning. Mater Des 30:1718–1725. https://doi.org/10.1016/j.matdes.2008.07.011

  17. Chen Y, Peng X, Kong L et al (2021) Defect inspection technologies for additive manufacturing. Int J Extrem Manuf 3:22002. https://doi.org/10.1088/2631-7990/abe0d0

    Article  Google Scholar 

  18. Kerwien S, Collings S, Liou F, Bytnar M (2013) Measurement science roadmap for metal-based additive manufacturing. NIST

  19. Taheri H, Shoaib MRBM, Koester LW et al (2017) Powder-based additive manufacturing-a review of types of defects, generation mechanisms, detection, property evaluation and metrology. Int J Addit Subtractive Mater Manuf 1:172–209

    Google Scholar 

  20. Sames WJ, List FA, Pannala S et al (2016) The metallurgy and processing science of metal additive manufacturing. Int Mater Rev 61:315–360. https://doi.org/10.1080/09506608.2015.1116649

    Article  Google Scholar 

  21. Kim FH, Kim FH, Moylan SP (2018) Literature review of metal additive manufacturing defects. US Department of Commerce, National Institute of Standards and Technology

  22. Everton SK, Hirsch M, Stravroulakis P et al (2016) Review of in-situ process monitoring and in-situ metrology for metal additive manufacturing. Mater Des 95:431–445. https://doi.org/10.1016/j.matdes.2016.01.099

  23. Chauveau D (2018) Review of NDT and process monitoring techniques usable to produce high-quality parts by welding or additive manufacturing. Weld World 62:1097–1118. https://doi.org/10.1007/s40194-018-0609-3

    Article  Google Scholar 

  24. Kim H, Lin Y, Tseng T-LB (2018) A review on quality control in additive manufacturing. Rapid Prototyp J 24:645–669. https://doi.org/10.1108/RPJ-03-2017-0048

    Article  Google Scholar 

  25. Koester L, Taheri H, Bigelow T, Bond L (2018) Nondestructive testing for metal parts fabricated using powder based additive manufacturing. Mater Eval 76

  26. Tapia G, Elwany A (2014) A review on process monitoring and control in metal-based additive manufacturing. J Manuf Sci Eng 136. https://doi.org/10.1115/1.4028540

    Article  Google Scholar 

  27. Thompson A, Maskery I, Leach RK (2016) X-ray computed tomography for additive manufacturing: a review. Meas Sci Technol 27:72001. https://doi.org/10.1088/0957-0233/27/7/072001

    Article  Google Scholar 

  28. Pejryd L, Karlsson P, Hällgren S, Kahlin M (2016) Non-destructive evaluation of internal defects in additive manufactured aluminium. In European Congress and Exhibition on Powder Metallurgy. European PM Conference Proceeding 1–7

  29. Lu QY, Wong CH (2018) Additive manufacturing process monitoring and control by non-destructive testing techniques: challenges and in-process monitoring. Virtual Phys Prototyp 13:39–48. https://doi.org/10.1080/17452759.2017.1351201

    Article  Google Scholar 

  30. Ladewig A, Schlick G, Zenzinger G et al (2017) Thermography for quality assurance in an additive manufacturing process

  31. Aminzadeh M, Kurfess TR (2019) Online quality inspection using Bayesian classification in powder-bed additive manufacturing from high-resolution visual camera images. J Intell Manuf 30:2505–2523. https://doi.org/10.1007/s10845-018-1412-0

    Article  Google Scholar 

  32. Slotwinski JA, Garboczi EJ, Hebenstreit KM (2014) Porosity measurements and analysis for metal additive manufacturing process control. J Res Natl Inst Stand Technol 119:494–528. https://doi.org/10.6028/jres.119.019

    Article  Google Scholar 

  33. Cerniglia D, Scafidi M, Pantano A, Rudlin J (2015) Inspection of additive-manufactured layered components. Ultrasonics 62:292–298. https://doi.org/10.1016/j.ultras.2015.06.001

  34. ASTM International (2017) ASTM E3–11(2017) Standard guide for preparation of metallographic specimens

  35. ASTM International (2015) ASTM E407–07(2015)e1: Standard practice for microetching metals and alloys

  36. International Organization for Standardization. ISO 4288 (1996) Geometrical product specifications (GPS) — surface texture: profile method — rules and procedures for the assessment of surface texture

  37. Pereira JC, Borovkov H, Zubiri F et al (2021) Optimization of thin walls with sharp corners in SS316L and IN718 alloys manufactured with laser metal deposition. J Manuf Mater Process 5. https://doi.org/10.3390/jmmp5010005

    Article  Google Scholar 

Download references

Funding

The study was supported by the Basque Government (Departamento de Desarrollo Económico e Infraestructuras del Gobierno Vasco, Programa ELKARTEK Convocatorias 2019 y 2021) through PROCODA (grant KK-2019/00004) and OPTICED (KK-2021/00003) projects, respectively, and supported by the Ministry of Science and innovation of the Spain Government through the program “Ayudas destinadas a centros tecnológicos de excelencia CERVERA año 2019” from CDTI (Centro para el Desarrollo Tecnológico Industrial) in the frame of CEFAM Project, grant CER-20191005.

Author information

Authors and Affiliations

  1. LORTEK Technological Centre, Basque Research and Technology Alliance (BRTA), Arranomendia kalea 4A, 20240, Ordizia, Spain

    Juan Carlos Pereira, Fidel Zubiri & Maria Jose Garmendia

  2. TEKNIKER, Basque Research and Technology Alliance (BRTA), Calle Iñaki Goenaga 5, 20600, Eibar, Gipuzkoa, Spain

    Mikel Tena

  3. Department of Mechanical Engineering, University of the Basque Country (UPV/EHU), Ingeniero Torres Quevedo Plaza, 1, 48013, Bilbao, Spain

    Haizea Gonzalez & Luis Norberto López de Lacalle

Authors
  1. Juan Carlos Pereira
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. Fidel Zubiri
    View author publications

    You can also search for this author in PubMed Google Scholar

  3. Maria Jose Garmendia
    View author publications

    You can also search for this author in PubMed Google Scholar

  4. Mikel Tena
    View author publications

    You can also search for this author in PubMed Google Scholar

  5. Haizea Gonzalez
    View author publications

    You can also search for this author in PubMed Google Scholar

  6. Luis Norberto López de Lacalle
    View author publications

    You can also search for this author in PubMed Google Scholar

Corresponding author

Correspondence to Juan Carlos Pereira.

Ethics declarations

Ethics approval

Not applicable.

Consent to participate

All the authors give their permission to participate and disseminate this work.

Consent for publication

All the authors give their authorization to publish this work.

Competing interests

The authors declare no competing interests.

Additional information

Publisher's note

Springer Nature remains neutral with regard to jurisdictional claims in published maps and institutional affiliations.

Rights and permissions

Reprints and permissions

About this article

Check for updates. Verify currency and authenticity via CrossMark

Cite this article

Pereira, J.C., Zubiri, F., Garmendia, M.J. et al. Study of laser metal deposition additive manufacturing, CNC milling, and NDT ultrasonic inspection of IN718 alloy preforms. Int J Adv Manuf Technol 120, 2385–2406 (2022). https://doi.org/10.1007/s00170-022-08905-x

Download citation

  • Received:

  • Accepted:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s00170-022-08905-x

Keywords

Search

Navigation