ASTM E3166-20e1
(Guide)Standard Guide for Nondestructive Examination of Metal Additively Manufactured Aerospace Parts After Build
Standard Guide for Nondestructive Examination of Metal Additively Manufactured Aerospace Parts After Build
SIGNIFICANCE AND USE
4.1 Metal parts made by additive manufacturing differ from their traditional metal counterparts made by forging, casting, or welding. Additive manufacturing produces layers melted or sintered on top of each other. The part’s shape is controlled by a computer as well as by the layers. The computer directs energy from a laser or electron beam onto a powder bed or wire input material. These processing approaches have the potential of creating flaws that are undesirable in the as-built or finished part. In general, processing parameter anomalies and disruptions during a build may induce such “flaws.” Flaws can also be introduced because of contaminants present in the input material.
4.2 Established NDT procedures such as those given in ASTM E07 standards are the basis for the NDT procedures discussed in this guide. These NDT procedures are used to inspect production parts before or after post-processing or finishing operations, or after receipt of finished parts by the end user prior to installation. The NDT procedures described in this guide are based on procedures developed for conventionally manufactured cast, wrought, or welded production parts.
4.3 Application of the NDT procedures discussed in this guide is intended to reduce the likelihood of material or component failure, thus mitigating or eliminating the attendant risks associated with loss of function, and possibly, the loss of ground support personnel, crew, or mission.
4.4 Input Materials—The input materials covered in this guide consist of, but are not limited to, ones made from aluminum alloys, titanium alloys, nickel-based alloys, cobalt-chromium alloys, and stainless steels. Input materials are either powders or wire.
Note 3: When electron beams are used, the beam couples effectively with any electrically conductive material, including aluminum and copper-based alloys.
4.4.1 Powders—High-quality powders required for AM process are produced by (1) plasma atomization, (2) inert gas atomizati...
SCOPE
1.1 This guide discusses the use of established and emerging nondestructive testing (NDT) procedures used to inspect metal parts made by additive manufacturing (AM).
1.2 The NDT procedures covered produce data related to and affected by microstructure, part geometry, part complexity, surface finish, and the different AM processes used.
1.3 The parts tested by the procedures covered in this guide are used in aerospace applications; therefore, the inspection requirements for discontinuities and inspection points in general are different and more stringent than for materials and components used in non-aerospace applications.
1.4 The metal materials under consideration include, but are not limited to, aluminum alloys, titanium alloys, nickel-based alloys, cobalt-chromium alloys, and stainless steels.
1.5 The manufacturing processes considered use powder and wire feedstock, and laser or electron energy sources. Specific powder bed fusion (PBF) and directed energy deposition (DED) processes are discussed.
1.6 This guide discusses NDT of parts after they have been fabricated. Parts will exist in one of three possible states: (1) raw, as-built parts before post-processing (heat treating, hot isostatic pressing, machining, etc.), (2) intermediately machined parts, or (3) finished parts after all post-processing is completed.
1.7 The NDT procedures discussed in this guide are used by cognizant engineering organizations to detect both surface and volumetric flaws in as-built (raw) and post-processed (finished) parts.
1.8 The NDT procedures discussed in this guide are computed tomography (CT, Section 7, including microfocus CT), eddy current testing (ET, Section 8), optical metrology (MET, Section 9), penetrant testing (PT, Section 10), process compensated resonance testing (PCRT, Section 11), radiographic testing (RT, Section 12), infrared thermography (IRT, Section 13), and ultrasonic testing (UT, Section 14)....
General Information
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Standards Content (Sample)
This international standard was developed in accordance with internationally recognized principles on standardization established in the Decision on Principles for the
Development of International Standards, Guides and Recommendations issued by the World Trade Organization Technical Barriers to Trade (TBT) Committee.
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Designation: E3166 − 20
Standard Guide for
Nondestructive Examination of Metal Additively
1
Manufactured Aerospace Parts After Build
This standard is issued under the fixed designation E3166; the number immediately following the designation indicates the year of
original adoption or, in the case of revision, the year of last revision.Anumber in parentheses indicates the year of last reapproval.A
superscript epsilon (´) indicates an editorial change since the last revision or reapproval.
1
ε NOTE—The caption for Fig. 10 was editorially corrected in August 2020.
1. Scope Section9),penetranttesting(PT,Section10),processcompen-
sated resonance testing (PCRT, Section 11), radiographic
1.1 This guide discusses the use of established and emerg-
testing (RT, Section 12), infrared thermography (IRT, Section
ing nondestructive testing (NDT) procedures used to inspect
13), and ultrasonic testing (UT, Section 14). Other NDT
metal parts made by additive manufacturing (AM).
procedures such as leak testing (LT) and magnetic particle
1.2 The NDT procedures covered produce data related to
testing (MT), which have known utility for inspection of AM
andaffectedbymicrostructure,partgeometry,partcomplexity,
parts, are not covered in this guide.
surface finish, and the different AM processes used.
1.9 Practicesandguidanceforin-processmonitoringduring
1.3 The parts tested by the procedures covered in this guide
the build, including guidance on sensor selection and in-
are used in aerospace applications; therefore, the inspection
process quality assurance, are not covered in this guide.
requirements for discontinuities and inspection points in gen-
1.10 This guide is based largely on established procedures
eral are different and more stringent than for materials and
under the jurisdiction of ASTM Committee E07 on Nonde-
components used in non-aerospace applications.
structive Testing and is the direct responsibility of the appro-
1.4 Themetalmaterialsunderconsiderationinclude,butare
priate subcommittee therein.
not limited to, aluminum alloys, titanium alloys, nickel-based
1.11 This guide does not recommend a specific course of
alloys, cobalt-chromium alloys, and stainless steels.
action for application of NDT to AM parts. It is intended to
1.5 The manufacturing processes considered use powder
increase the awareness of established NDT procedures from
and wire feedstock, and laser or electron energy sources.
the NDT perspective.
Specific powder bed fusion (PBF) and directed energy depo-
1.12 Recommendationsaboutthecontrolofinputmaterials,
sition (DED) processes are discussed.
process equipment calibration, manufacturing processes, and
1.6 This guide discusses NDT of parts after they have been
post-processing are beyond the scope of this guide and are
fabricated. Parts will exist in one of three possible states: (1)
under the jurisdiction of ASTM Committee F42 on Additive
raw, as-built parts before post-processing (heat treating, hot
Manufacturing Technologies. Standards under the jurisdiction
isostatic pressing, machining, etc.), (2) intermediately ma-
ofASTM F42 or equivalent are followed whenever possible to
chined parts, or (3) finished parts after all post-processing is
ensure reproducible parts suitable for NDT are made.
completed.
1.13 Recommendations about the inspection requirements
1.7 TheNDTproceduresdiscussedinthisguideareusedby
and management of fracture critical AM parts are beyond the
cognizant engineering organizations to detect both surface and
scope of this guide. Recommendations on fatigue, fracture
volumetricflawsinas-built(raw)andpost-processed(finished)
mechanics, and fracture control are found in appropriate end
parts.
user requirements documents, and in standards under the
jurisdictionofASTMCommitteeE08onFatigueandFracture.
1.8 The NDT procedures discussed in this guide are com-
puted tomography (CT, Section 7, including microfocus CT),
NOTE 1—To determine the deformation and fatigue properties of metal
eddy current testing (ET, Section 8), optical metrology (MET, parts made by additive manufacturing using destructive tests, consult
Guide F3122.
NOTE 2—To quantify the risks associated with fracture critical AM
parts, it is incumbent upon the structural assessment community, such as
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This guide is under the jurisdiction ofASTM Committee E07 on Nondestruc-
ASTM Committee E08 on Fatigue and Fracture, to define critical initial
tiveTesting and is the direct responsibility of Subcommittee E07.10 on Specialized
flaw sizes (CIFS) for the part to define the objectives of the NDT.
NDT Methods.
1.14 This guide does not specify accept-reject criteria used
Current edition approved Feb. 1, 2020. Published July 202
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