Quality is an important consideration in
any manufacturing process, but with additive manufacturing, new factors come
into play that simply aren’t major concerns in conventional machining. When you
receive a block or billet of material for machining, certain assumptions can be
made about the metallurgical qualities of the metal, from the crystal structure
to its internal stresses.
With metal additive manufacturing,
especially powder-based technologies, everything from part design, to powder
quality to build conditions can introduce variables in the quality of the
material. On top of this, destructive testing may not be desirable for an
additive-based production process. With the internal geometries possible in 3D-printed
parts, being able to see and scan the entire structure is valuable. One way to
do this is with industrial CT scanning.
High-Energy Industrial CT Scanning Service
Jesse
Garant Metrology Center recently announced the launch of its new high
energy industrial CT scanning service. With this system, the company will be
the only private lab in the world to provide this specialized inspection
service. The new capability is an option for non-destructive testing and support
innovation within advanced manufacturing.
According to Jesse Garant Metrology Center, the system is the first of its kind to pair a 3 MeV cone-beam x-ray source with a large format 2k x 2k flat panel digital detector. It will be able to accommodate rapid inspection of mid-size parts, up to 44.5 inches (1130mm) in diameter by 63 inches (1600mm) in height. The new capabilities will also directly support the growing additive manufacturing industry, allowing for feasible internal inspection and validation of 3D-printed parts made from ferrous and non-ferrous materials.
The company aims to expand the applicability
of industrial CT technology to various part sizes and densities. This will
allow for internal inspection and dimensional validation of 3D-printed parts
that would otherwise go into production without proper inspection. The
technology will also provide useful analyses for additive manufacturing,
including identification of defects like porosity, residual powders, first
article inspection, wall thickness variations
and actual to nominal comparisons for out of tolerance features.
System Provides New Opportunities for Complex Part Designs
“We’re helping manufacturers qualify and
validate parts that either weren’t possible because of limitations with existing
technologies or weren’t feasible because the service was too costly or took too
much time,” explained Jesse Garant, president of the center.
The costly endeavor required a $4.5 million investment in technology as well as three years of planning, design, development and construction to reach full operation. The new system required sourcing from both local and international manufacturers, vendors, and specialists, including the construction of the largest 1m x 1m (3.28’ x 3.28’) flat panel detector in the world.
With federal operational permits currently in place, the new system is now live. Jesse Garant Metrology Center is currently taking on orders from companies who wish to access this innovative technology during the system’s ramp up period.
For more information, visit the Jesse Garant Metrology Center website.