The challenge for manufacturers is knowing whether a cast or forged metal part will perform equally or better if additively manufactured. MRL (Materials Resources LLC), an additive metals research and manufacturing company, and defense contractor in Dayton, Ohio, focused on metallic additively manufactured materials, is answering this question. MRL solves this problem for customers using mechanical testing, computer modeling, artificial intelligence, optimized 3D printers, and now computed tomography (CT).

To predict the fatigue behavior and strength, MRL researchers needed to see inside additively manufactured sample parts. MRL’s recent acquisition of a Yxlon FF35 CT system allows researchers to investigate structural irregularities such as pores, cavities, cracks, and geometrical deviations such as insufficient wall thickness and then relate them to the overall part performance.

The FF35 CT is a high-resolution computed tomography system designed to achieve exact non-destructive testing results for small-to-medium-sized parts up to about 20” x 32”.

Read more in this quarter’s Metal Additive Manufacturing.

3D visualization of the lack of fusion defects as captured by the melt pool monitor sensors. An artifact of the word "DEFECT" is visible in the sensor data (left image) and confirmed by the Yxlon FF35 CT system.