ASTM E3166-20
(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)....
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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. Scope testing (RT, Section 12), infrared thermography (IRT, Section
13), and ultrasonic testing (UT, Section 14). Other NDT
1.1 This guide discusses the use of established and emerg-
procedures such as leak testing (LT) and magnetic particle
ing nondestructive testing (NDT) procedures used to inspect
testing (MT), which have known utility for inspection of AM
metal parts made by additive manufacturing (AM).
parts, are not covered in this guide.
1.2 The NDT procedures covered produce data related to
1.9 Practicesandguidanceforin-processmonitoringduring
andaffectedbymicrostructure,partgeometry,partcomplexity,
the build, including guidance on sensor selection and in-
surface finish, and the different AM processes used.
process quality assurance, are not covered in this guide.
1.3 The parts tested by the procedures covered in this guide
are used in aerospace applications; therefore, the inspection
1.10 This guide is based largely on established procedures
requirements for discontinuities and inspection points in gen-
under the jurisdiction of ASTM Committee E07 on Nonde-
eral are different and more stringent than for materials and
structive Testing and is the direct responsibility of the appro-
components used in non-aerospace applications.
priate subcommittee therein.
1.4 Themetalmaterialsunderconsiderationinclude,butare
1.11 This guide does not recommend a specific course of
not limited to, aluminum alloys, titanium alloys, nickel-based
action for application of NDT to AM parts. It is intended to
alloys, cobalt-chromium alloys, and stainless steels.
increase the awareness of established NDT procedures from
1.5 The manufacturing processes considered use powder the NDT perspective.
and wire feedstock, and laser or electron energy sources.
1.12 Recommendationsaboutthecontrolofinputmaterials,
Specific powder bed fusion (PBF) and directed energy depo-
process equipment calibration, manufacturing processes, and
sition (DED) processes are discussed.
post-processing are beyond the scope of this guide and are
1.6 This guide discusses NDT of parts after they have been
under the jurisdiction of ASTM Committee F42 on Additive
fabricated. Parts will exist in one of three possible states: (1)
Manufacturing Technologies. Standards under the jurisdiction
raw, as-built parts before post-processing (heat treating, hot
ofASTM F42 or equivalent are followed whenever possible to
isostatic pressing, machining, etc.), (2) intermediately ma-
ensure reproducible parts suitable for NDT are made.
chined parts, or (3) finished parts after all post-processing is
1.13 Recommendations about the inspection requirements
completed.
and management of fracture critical AM parts are beyond the
1.7 TheNDTproceduresdiscussedinthisguideareusedby
scope of this guide. Recommendations on fatigue, fracture
cognizant engineering organizations to detect both surface and
mechanics, and fracture control are found in appropriate end
volumetricflawsinas-built(raw)andpost-processed(finished)
user requirements documents, and in standards under the
parts.
jurisdictionofASTMCommitteeE08onFatigueandFracture.
1.8 The NDT procedures discussed in this guide are com-
NOTE 1—To determine the deformation and fatigue properties of metal
puted tomography (CT, Section 7, including microfocus CT),
parts made by additive manufacturing using destructive tests, consult
eddy current testing (ET, Section 8), optical metrology (MET,
Guide F3122.
Section9),penetranttesting(PT,Section10),processcompen-
NOTE 2—To quantify the risks associated with fracture critical AM
sated resonance testing (PCRT, Section 11), radiographic parts, it is incumbent upon the structural assessment community, such as
ASTM Committee E08 on Fatigue and Fracture, to define critical initial
flaw sizes (CIFS) for the part to define the objectives of the NDT.
1
This guide is under the jurisdiction ofASTM Committee E07 on Nondestruc-
1.14 This guide does not specify accept-reject criteria used
tiveTesting and is the direct responsibility of Subcommittee E07.10 on Specialized
in procurement or as a means for approval of AM parts for
NDT Methods.
service.Anyaccept-rejectcriteriaaregivensolelyforpurposes
Current edition approved Feb. 1, 2020. Published July 2020. DOI: 10.1520/
E3166-20. of illustration and comparison.
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