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Complimentary

NDT Demonstration

Discover why nonlinear resonance is the ideal non-destructive testing solution for AM medical device part qualification.

✔️ Inspect the devices you actually intend to use, not unreliable test specimens.

✔️ Identify flaws in complex medical devices even with rough surface finish.

✔️ Rapid non-destructive tests deliver reliable flaw data in under a minute.

Let Theta Technologies show you how straight-forward the part qualification of AM medical devices can be.

Book Your NDT Demonstration

To book your complimentary nonlinear resonance non-destructive test simply fill out your details using this form and one of our team of technical specialists will be in touch to discuss your individual requirements. 

AM medical device implants featuring complex geometries

Featured Article

The benefits of using nonlinear resonance NDT for the part qualification of AM medical devices

Additive manufacturing (AM) offers unprecedented opportunities for creating customised medical devices, implants, and prosthetics. However, with this innovation comes the critical challenge of ensuring that these devices meet the strict safety and reliability standards required for medical applications. Explore the future of AM medical device part qualification.

NDT Resources and Articles

AM medical device implants featuring complex geometries

Featured Article

The benefits of using nonlinear resonance NDT for the part qualification of AM medical devices

Additive manufacturing (AM) offers unprecedented opportunities for creating customised medical devices, implants, and prosthetics. However, with this innovation comes the critical challenge of ensuring that these devices meet the strict safety and reliability standards required for medical applications. Explore the future of AM medical device part qualification.

Recent Articles

Resources to help you navigate the world of NDT for additive manufacturing.

We understand the part qualification challenges faced by those embracing additive manufacturing. That’s why we’re committed to providing you with valuable and insightful content to help navigate this increasingly complex landscape.

Explore our latest articles on a range of key industry topics:

An AM aerospace part being subject to a nonlinear resonance NDT test

Topic: AM Flaw Detection

AM flaw types, the consequences of leaving undetected, and the NDT solution you need

Learn about the common flaw types found within additive manufactured components and discover how nonlinear resonance NDT can help identify them before they become an issue.

READ NOW

An AM aerospace part being subject to a nonlinear resonance NDT test

Topic: Additive Manufacturing

How to solve additive manufacturing part qualification challenges with effective NDT

Addressing the unique part inspection challenges of additive manufacturing is continuing to be one of the biggest obstacles preventing its wider adoption. Learn how to solve these challenges.

READ NOW

An AM aerospace part being subject to a nonlinear resonance NDT test

Topic: AM Post-Processing

Reducing the risk of adding value to AM parts at post-processing with immediate inspection

Deploying effective NDT earlier in your manufacturing process is key to reducing unnecessary value being added to defective parts during post-processing. Find out how nonlinear resonance can help.

READ NOW

Register for an Exclusive On-Demand Webinar:

Explore the power of Nonlinear Resonance NDT for complex AM parts

Discover how nonlinear resonance can transform your inspection processes for additive manufacturing parts. Register for our exclusive webinar to explore Theta Technologies’ groundbreaking NDT technique.

AVAILABLE IN

Day(s)

:

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:

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What You Will Learn

How nonlinear resonance NDT compares to traditional qualification techniques like X-ray CT

Discover the key mechanisms that indicate flaws (e.g., clapping flaw behaviour)

Hear about real-world applications for detecting flaws in complex AM parts using nonlinear resonance

RD1-TT, Theta Technologies nonlinear resonance NDT solution

What is

Nonlinear Resonance

Non-Destructive Testing?

Theta Technologies’ patented non-destructive testing technology is designed to offer manufacturers of high-performance components a faster, more reliable, and cost-effective part qualification solution. This innovative technology is conveniently packaged into the world’s only nonlinear resonance NDT solution, RD1-TT. With seamless integration into any existing manufacturing workflow, and the ability to deliver go/no go NDT results in under a minute, RD1-TT is the ideal part qualification technology for critical manufacture.

Exclusive

On-Demand

NDT Webinar

Explore the power of nonlinear resonance NDT for complex AM part qualification

NDT webinar
With RD1-TT, we’ve turned years of R&D into a real-world solution that can dramatically improve part inspection for additive manufacturing

James Watts, CEO, Theta Technologies

Your Webinar Host

James Watts, CEO, Theta Technologies

James completed a Ph.D. in Semiconductor Physics at the University of Exeter, before working on radar hardware design and analysis at the UK Defence Research Agency (Now QineticQ). Moving back to the South West in 2005, he was Chief Engineer, then Chief Executive at Flann Microwave, an SME with an international reputation for the design and manufacture of RF and microwave equipment for telecommunications, space, defence, and medical applications. 

Your Questions Answered:
When will this webinar be available to watch?

This on-demand webinar will be available to watch on the 30th October 2024 around 12pm. The webinar will only be available to those who register via the form below.

How long is this webinar?

We’ve decided to keep this introductory webinar as short as possible, without sparing the detail. The key information you need to know about our nonlinear resonance NDT has been condensed into an easily digestible 15-minute webinar.

What industries will benefit most from nonlinear resonance NDT?

Anyone manufacturing components for safety-critical applications such as aerospace, medical, defence, automotive, power generation, or oil and gas can benefit from nonlinear resonance NDT. This technology can help identify smaller flaws than any other non-destructive testing method before they become an issue. You can learn more about the benefits of nonlinear resonance NDT by visiting our solutions page.

How do I access the webinar?

Simply register your interest in this webinar using the form below and upon release (30th October 2024) you will be emailed an exclusive access code to gain admission to the webinar here on our website. You will then be able to watch at a time most convenient to you any time you wish.     

Register for this Exclusive

On-Demand Webinar

This exclusive webinar is packed full of detailed insights on how Theta Technologies’ nonlinear resonance NDT can enable you to deploy faster, more reliable, and more cost-effective part qualification methods. Register now to receive access and learn about this exciting NDT technology.

Theta Technologies' animated wave logo

Additive Manufacturing:

The flaw types, the consequences of leaving them undetected, and the NDT solution you’ve been looking for.

Meet The Team

Behind Our Technology

With a wealth of experience in various industries, our team of experts are ideally placed to offer you the most valuable insights into how our innovative non-destructive testing solution can enhance your production of additive manufactured parts for safety-critical applications.

Whether you’re exploring AM for specific applications such as spaceflight or medical devices, eager to learn more about part inspection pitfalls, or you’re interested in adopting a more sustainable approach, there’s something for everyone.

JAMES WATTS

CHIEF EXECUTIVE OFFICER

AM, Spaceflight Applications and NDT

DANIEL SANMARTIN

R&D MANAGER

NDT for AM Medical Device Applications

KRIS DELANEY

OPERATIONS MANAGER

Championing Sustainability in AM

What is

Non-Destructive Testing?

Non-Destructive Testing (NDT) is a crucial evaluation method used in manufacturing and engineering to assess the integrity and quality of materials, components, or systems without causing any unnecessary damage.

By utilising advanced techniques such as ultrasonic testing, radiography, and our very own nonlinear resonance, NDT enables manufacturers to detect defects, ensure product reliability, and maintain safety standards, especially within high-stakes industries. NDT is widely employed across various industries, including aerospace, automotive, and medical, where the ability to verify the integrity of parts without compromising their functionality is paramount.

Detect Signs of Weakness

NDT allows engineers to detect early signs of weakness or potential failure in material structures and components. This crucial pre-emptive approach ensures that flaw initiation features such as micro-cracks, voids or porosity, are identified before they lead to costly or catastrophic failures, enhancing overall safety and performance.

Test Without Destruction

One of the key advantages of non-destructive testing is its ability to test parts without causing any damage. Unlike destructive testing methods such as tensile stress testing, NDT preserves the integrity of the component, making it possible to inspect critical parts repeatedly throughout their lifecycle without compromising their usability. This also results in less material waste.

Predict Part Operation

NDT not only identifies existing defects but also provides valuable insights into how a part may perform under operational conditions. By analysing the data gathered during testing, manufacturers can predict the lifespan and operational reliability of components, enabling more informed maintenance and production decisions.

Topics

Additive Manufacturing Flaw Types and Flaw Detection

Industry Applications

Aerospace, Defence, Motorsport, Automotive, Oil and Gas, Medical, Power Generation, Renewables, Research Institutes.

Industry Applications

From medical implants to spaceflight components, ensuring the integrity and reliability of additive-manufactured parts is not just important but urgent, particularly in safety-critical applications where failure can have catastrophic consequences. Immediate action is essential to prevent potential disasters and safeguard lives, making it imperative to address part inspection issues with the highest priority.

An icon representing faster part inspection

Faster Part Inspection

Nonlinear resonance is the first NDT solution capable of performing whole-body inspection on real parts in under a minute.

An icon representing design freedom

Freedom of Design

Unlock the full potential of additive manufacturing for critical applications with the ability to test complex shapes.

An icon representing return on investment (ROI)

Reduced Cost Per Part

Improve business margins and receive a faster return on your investment with more cost-effective part qualification.

NDT Insights

and Innovations

Theta Technologies are not only committed to assisting the advancement of additive manufacturing technology through effective non-destructive testing solutions, but through knowledge sharing. That’s why we have created a series of insightful articles to help you navigate key additive manufacturing topics and challenges.

2

Additive Manufacturing: The types of flaws, the consequences of leaving them undetected, and the NDT solution you’ve been looking for.

Discover the common flaw types found within additive manufactured components and how nonlinear resonance NDT can help identify them before they become an issue.

Read The Article

2

Additive Manufacturing: The part qualification challenges you face and how to solve them with effective non-destructive testing.

Addressing the unique part inspection challenges of AM is continuing to be one of the biggest obstacles for widespread adoption. Find out why and learn how to solve them with innovative non-destructive testing methods.

Read The Article

2

Eliminate the risk of adding value to flawed AM components at post-processing with more immediate part inspection.

Deploying effective NDT earlier in your manufacturing process to assess its justification for post-processing is key to reducing risk and costs. Find out how nonlinear resonance can help do just that.

Read The Article

2

Nonlinear resonance NDT: Setting the standards for additive manufacturing non-destructive testing solutions.

Understand your additive-manufactured components like never before and resolve the key AM inspection challenges with Theta Technologies’ revolutionary non-destructive testing technology. 

Read The Article

Theta Technologies:

Innovators in NDT

Our patented nonlinear resonance NDT technology is the world’s only practical part qualification solution for complex 3D-printed metals produced at scale. Pioneering flaw detection with unmatched speed and accuracy, RD1-TT is indispensable for AM parts manufactured for critical applications and plays a crucial role in the implementation of Industry 4.0.

inside AM: Aug 2024: Episode #3
Advancing Additive Manufacturing: Insights from Enrico Gallino on Innovations, Challenges, and Future Directions

In this episode, we sit down with Senior Engineer at Ricoh 3D, Enrico Gallino to explore the cutting-edge advancements in additive manufacturing. We delve into the transformative potential of composite materials and discuss the key comparisons between tensile stress testing and nonlinear resonance NDT for quality assurance of AM parts. Enrico also shares his insights on how collaboration within the AM ecosystem is key to unlocking broader adoption and innovation.

Additive Manufacturing,
Space Applications and NDT

We’re thrilled to unveil our brand new ‘Team Behind The Tech’ feature where we quiz members of the Theta Technologies’ team about pressing industry topics. First up is Theta Technologies CEO, Prof. James Watts where we gain his valuable insights on the future of additive manufacturing for space applications, and the role that non-destructive testing can play in enhancing this exciting industry.

James Watts

CEO, Theta Technologies

James completed a Ph.D. in Semiconductor Physics at the University of Exeter, before working on radar hardware design and analysis at the UK Defence Research Agency (Now QineticQ). Moving back to the South West in 2005, he was Chief Engineer, then Chief Executive at Flann Microwave, an SME with an international reputation for the design and manufacture of RF and microwave equipment for telecommunications, space, defence, and medical applications. As Chief Executive Officer, James is responsible for guiding the company to turn its heritage of world-leading research in nonlinear acoustics into products that make a difference.

” AM is really exciting for Space”

Assessing Nonlinear Resonance NDT potential to aid additive manufacturing adoption in space applications.

Additive Manufacturing (AM) is transforming the aerospace and space industries, offering the ability to produce parts with increased complexity and reduced mass. This capability is crucial for space applications, where every gram saved translates to substantial cost savings and enhanced mission capabilities. However, the very versatility that makes AM so appealing also introduces significant challenges in part inspection. Ensuring the reliability and structural integrity of these parts is paramount, particularly for the harsh and unforgiving conditions of space.

In this feature, we delve into the groundbreaking potential of Nonlinear Resonance (NLR) Non-Destructive Testing (NDT) technology for space applications. We sit down with Professor James Watts, CEO of Theta Technologies, to explore how this innovative NLR technology is overcoming the inspection challenges posed by AM parts, ensuring that they meet the stringent demands of space missions.

The Interview

James, we’re here to talk about space and how Theta’s technology can be deployed to benefit that area. Before we get to that, let’s talk about the opportunity within the space that additive manufacturing has.

Well, we think that AM is really exciting for space because it gives the opportunity to build parts that are much, much lower in mass. Maybe mass reductions of 75%. That means that these parts can be multi-functional, and we can make a real difference to the volume of payloads, the mass of payload, and the size of space flight hardware.

We know that the versatility of additive manufacturing has caused some issues when it comes to part inspection. What’s the importance, certainly within a space context in making sure these parts don’t fail?

So, the main thing with implementing a technology like AM for aerospace and space flight is proving that the parts that you’re going to make, and you’re going to deploy on those missions are going to survive. For that, aerospace and space typically use non-destructive testing, which is great. But the downside with AM is that because you can achieve very, very complex shapes, surface finishes are complex, which is driving much more integration and much bigger parts, there really aren’t that many alternative techniques that are going to work for AM.

Really, X-ray CT is the only technique that is accepted for a non-destructive test for AM parts, but for larger parts, and parts made of denser alloys like Inconel, you just can’t get the resolution for detecting the sorts of flaws that you might be worried about in an AM part. That’s where our technique comes in, because it can detect flaws in parts that are much larger, and it really doesn’t care about the complexity of the parts that you present to it.

Other companies have started to move away from X-ray CT and started to put in-process imaging in place for their inspection process, but there are major pitfalls with that as well aren’t there?

In-process imaging is an effective way of assessing each layer as you build them, but it really doesn’t tell you what happens after that layer has been built. There might be thermal stresses in the parts that really start to accumulate only later in the build. These can easily cause cracking underneath the layer that’s being photographed.

Post-processing can also induce flaws. The support removal process is often quite brutal, and it’s very simple to induce a flaw during support removal, or de-powdering. It’s therefore quite important to have a technique to detect cracks or other flaws that are induced later in the build process.

” It really doesn’t care about the complexity of the parts you present to it.”

Nonlinear resonance looks set to fill that gap. Before we talk about how it’s going to assist the adoption of AM in the space industry, how does this technology work?

So, our technique, nonlinear resonance, works by exciting the part with an acoustic signal. Every mechanical part has a unique acoustic signature, and that’s because of the different features of the part. All have slightly different resonance frequencies, and they interact in different ways. By exciting the part in the right way, we can measure the spectral response of that part. That spectral response is unique for each part.

Even for parts that are normally identical, that are produced by AM, different amounts of support removal might mean that they’re physically slightly different. Usually they are designed so that that doesn’t matter. It doesn’t affect the operation of the part, but it does mean that the unique acoustic signature is different. So, we can’t just rely on the acoustic signature of a part and do spectroscopic comparisons.

Nonlinear Resonance takes that one step further and it looks to see how the unique signature changes as we change the excitation. For a good part, a part which doesn’t have any flaws in it, you wouldn’t expect to see any changes in the acoustic signature of a part. But when you excite a part that has a crack in it, at low amplitude of excitation, you get one acoustic signature, but when you turn the amplitude up, the signature changes. Those changes are the unique signature of a flaw, and they can only come from a flaw within the part.

So, our nonlinear resonance non-destructive test technique looks for those signatures of a flaw within the part. It doesn’t care what the shape of the part is, and it doesn’t care how different the parts are. Although we can measure that, it just looks for the unique signature of a flaw within the part.

Watch Our Walkthrough of a

Nonlinear Resonance Test

The sensitivity of a nonlinear resonance non-destructive test is far superior to any other inspection technology, meaning that it can easily identify even the smallest of flaws within an additive-manufactured component. See a nonlinear resonance non-destructive test in action as our very own Applications Engineer, Lydia takes you through a thorough step-by-step guide.

Where can this technology fill that gap that is perhaps left by techniques like X-ray and in-process imaging? Where is this most beneficial application in space manufacturing?

So, we see this being used in AM Parts, perhaps larger parts structural elements of a satellite engine components, or thrusters where those parts might be quite complex. They might have manifolds, pipes, fixings, heat-exchanger elements. Parts that are very, very complex, but as a solid, they should have a stable but unique acoustic signature. If we see a crack in one of those parts, we’d see that acoustic signature change as we increase the excitation. That would give us the indication that that part might be a flawed part and we can stop it before there’s lots and lots of post-processing. That later saves costs, time, and money, but we can also detect a part that might fail in service.

Finally, with effective part inspection, how big can AM be for Space applications?

AM is already seeing a lot of deployment within space and space flight. That is fantastic because it means that we’re starting to see the benefits of the technology being deployed. But it’s limited by the lack of good NDT and what I see is that as we’re able to prove that our NDT technique is capable of doing much better-quality validation of the parts, then there might be the opportunity to make parts that are even lower mass, even more optimised, and able to make a real difference to space flight hardware.

RD1-TT, Theta Technologies nonlinear resonance NDT solution

Introducing RD1-TT

The World’s Only

Nonlinear Resonance

Non-Destructive Testing Solution

Theta Technologies is at the forefront of part inspection transformation, ensuring that the next generation of space components meet the highest standards of safety and performance. RD1-TT, the world’s first nonlinear resonance testing solution circumvents the key testing challenges that has prevented widespread adoption of additive manufactured parts in critical applications like space, meaning that manufacturers can finally design, print and deploy these parts with confidence.

Nonlinear Resonance

Non-Destructive Testing

Theta Technologies’ patented nonlinear resonance non-destructive testing (NDT) technique is designed to offer manufacturers of increasingly complex additive-manufactured parts for safety-critical applications a more efficient, cost-effective flaw-detection solution.

Theta Technologies NDT specialists for additive manufacturing
Nonlinear resonance results data displayed on the screen of Theta Technologies' RD1-TT non-destructive testing machine.

Why invest in

nonlinear resonance NDT?

Theta Technologies is not only committed to assisting the advancement of additive manufacturing technology through effective non-destructive testing solutions, but through knowledge sharing. That’s why we have created a series of insightful articles to help you navigate key additive manufacturing topics and challenges.

Critical Manufacture icon

Critical Manufacture

Whether you are manufacturing AM components for aerospace, defence, power generation, or medical applications, nonlinear resonance NDT provides a rapid, reliable part qualification method when integrity is of paramount importance and failure is simply not an option.

A complex additive manufactured shape icon

Complex Structures

Proven testing techniques used to inspect traditional materials have struggled to provide comprehensive results when faced with the more complex internal geometries achievable through additive manufacturing. This has largely restricted the more complex parts to prototyping.

Scale manufacturing icon

Scale Manufacturing

Slow and expensive techniques such as X-ray CT scanning are not viable options for additive manufacturing at scale. This often restricts testing to samples instead of entire production batches, significantly increasing the possibility of leaving flawed components unidentified.

Theta Technologies' animated wave logo

Delivering a unique non-destructive testing solution offering significant time and cost savings for the detection of flaws in performance AM components.

An additive manufactured part being placed inside RD1-TT

How does nonlinear resonance

non-destructive testing work?

Nonlinear resonance is a differential measurement that initially establishes a low energy baseline acoustic signature for a specific part. This signature is unique to that component and is a result of the component’s geometry, material and manufacturing method.

battery icon

Energy Input Level

The part under test is excited using a low amplitude energy signal to establish a baseline signature. The energy level is then increased to exploit microscopic flaw behaviours of parts.

Excited part icon

Excitation of Component

The varying energy input levels excite the part under test into resonance. A detector system and Theta technologies’ unique algorithm then monitors the frequency response.

Frequency icon

Frequency Response

The frequency response from the varying energy levels input into the part during excitation would remain linear for a part that is flaw-free. A change in the signature indicates flaws.

A Flaw-Free Part

What To Expect

The part is initially excited using a lower energy signal to establish the component’s acoustic signature. Much like a fingerprint it is unique to the part and doesn’t change. Flaw-free parts result in the same scaled signature with the input energy increased.

A nonlinear resonance non-destructive test animation - how it works

A Flawed Part

What To Expect

Much like a flaw-free part, flawed parts unique acoustic signature scales in amplitude; however this scaled signature exhibits nonlinear behaviours when hidden flaws within the component are activated as a result of a nonlinear resonance non-destructive test.

How a nonlinear resonance NDT test works

Introducing RD1-TT

The World’s Only

Nonlinear Resonance

Non-Destructive Testing Solution

Exploiting Theta Technologies’ patented nonlinear resonance non-destructive testing technology, RD1-TT fits seamlessly into your existing manufacturing workflow to facilitate faster, more cost-effective AM part triage. No longer will you need to invest in expensive X-ray CT equipment or ship additive manufactured parts off-site for validation, thanks to RD1-TT.

RD1-TT, Theta Technologies nonlinear resonance NDT solution

A Nonlinear Resonance

Non-Destructive Test explained

See a nonlinear resonance non-destructive test in action as our very own Applications Engineer, Lydia takes you through a thorough step-by-step guide.

More Sensitive Testing,

More Flaws Detected

With a baseline “signature” established via a low amplitude excitation process, a controlled high energy signal is coupled into the component, which is sufficient to activate any closed, or hidden, flaws and produce nonlinear indications. These delicate measurements are then picked up and interpreted by our proprietary algorithm to help validate the integrity of the AM component.

The sensitivity of a nonlinear resonance non-destructive test is far superior to any other inspection technology, meaning that it can easily identify even the smallest of flaws within an additive-manufactured component.

Nonlinear Resonance

‘Damage Index’ Results Data

Results of individual tests are plotted in the form on a ‘damage index’ which helps to reveal parts of concern. Nonlinear resonance provides a figure of merit related to the number of flaw indications in the different acoustic signature of the parts under test. This does not categorically state whether a part is fit for its intended purpose or not, it simply highlights the parts at risk of failing in service.

NLR Results Example

Flaw-Free Production

All parts tested in this set show no or minimal signs of nonlinearity and fall below the tolerance threshold deemed acceptable by the customer. These results do not reveal the presence of defects within the batch.

To find out more about nonlinear resonance NDT or to discuss your NDT requirements in detail, book a meeting with our team.

NLR Results Example

Flawed Production

The nonlinear resonance test results for this production batch reveal a number of parts with high nonlinearity. Parts 002, 008, 012, 014, 015 and 019 exceed the tolerance threshold for nonlinearity and would pose potential risk if used for their intended application.

The Benefits Of

Nonlinear Resonance NDT

Nonlinear resonance NDT offers additive manufacturers a number of key advantages over other part inspection techniques on the market.

Rapid Test Speeds

Faster non-destructive testing opens up new opportunities for additive manufacturers. Nonlinear resonance NDT can test and identify flaws in AM parts in under a minute.

Immediate Inspection

Can be used to test AM parts prior to, and throughout various stages of the post-processing stage, even with the inherent rough surface finish associated with 3D printed metals.

Heightened Sensitivity

The highly sensitive nature of a nonlinear resonance non-destructive test reveals hidden details that cannot be identified with less sensitive part inspection techniques.

Surface Finish Agnostic

The rough surface finish associated with additive-manufactured metals has caused widespread challenges with part inspection. Nonlinear resonance NDT is unaffected by such conditions. 

Real Part Testing

Eliminates the need for producing test coupons alongside your production batch for tensile tests. Nonlinear resonance allows you to rapidly test the parts you intend to use.

More Sustainable Testing

Nonlinear resonance NDT allows for a more eco-conscious approach to part validation through low power usage, no requirement for hazardous chemicals, and faster testing.

Talk to

Our Team of

Technical Specialists

Connect with our team of technical experts today and explore how RD1-TT can help revolutionise your additive manufacturing processes.

Additive manufactured part being created through laser powder bed fusion technique.

Additive Manufacturing: The types of flaws, the consequences of leaving them undetected, and the NDT solution you’ve been looking for.

As additive manufacturing (AM) technology continues to evolve, it is increasingly being adopted across a variety of industries due to its ability to produce complex, high-precision parts. From medical implants to aerospace components, the potential of AM to revolutionise manufacturing processes is significant. However, alongside these advancements comes the critical need to ensure the integrity and reliability of the parts produced. This is particularly important in safety-critical applications where failure can have severe consequences.

Detailed close-up of an additive manufactured metal bar.

The Rise of Additive Manufacturing

Additive manufacturing, particularly using techniques such as Laser Powder Bed Fusion (L-PBF) has found applications in numerous sectors due to its incredible versatility and precision. In the medical field, personalised implants are becoming common practice, offering customised solutions for optimal patient care. The automotive and aerospace industries are also capitalising on the advantages of metal L-PBF components, which allow for lightweight, durable, and complex designs that are difficult to achieve with traditional manufacturing methods. These modern designs provide cost savings through reduced numbers of parts in assemblies, simpler production processes and a streamlined supply chain.

Furthermore, industries such as dentistry and jewellery are utilising AM for the fabrication of directly printed components with microscale resolution. The energy sector, including oil and gas and power generation), and motorsport, is exploring the use of AM for engineering devices, tools, and sensors like heat exchangers and heat sinks. The ability to create customised functional products is opening a wide range of engineering applications for AM technology.

 

The critical importance of detecting flaws

Despite its many advantages, AM is not immune to all the issues that plague traditional manufacturing methods. Defects or flaws in AM parts can significantly impact the mechanical properties and overall performance of the final product. As a result, it is essential to continually refine AM processes and implement robust inspection methods to minimise defects and ensure the reliability of produced parts. But effective inspection with the goal of identifying the most common flaws within AM components has proven to be far from straight-forward.

 

Common types of flaws in additive-manufactured parts

  1. Trapped Powder

Trapped powder is a unique and potentially significant issue within AM components, especially those with intricate air channels or ducts. For example, trapped powder in a cooling duct of a heat exchanger can lead to blockages, impeding airflow and rendering the component ineffective. In critical applications like automotive engines or aircraft systems, this can increase the risk of overheating and overall system failure.

  1. Lack of Fusion

Lack of fusion defects, typically found within additive manufactured components produced via laser powder bed fusion can occur among the layers during printing. Put simply, the individual layers haven’t fused together during the print process, creating potential areas of weakness or crack initiation sites. This defect can prove detrimental to the overall mechanical properties of your additive-manufactured component, and indeed the structure’s integrity, making it vulnerable to failure particularly if used for an application prone to intense vibrations or impact.

  1. Porosity

Porosity refers to small, often microscopic voids within the material. In pressure vessels used in the oil and gas, or chemical storage industries, porosity can create weak points in the structure, increasing the risk of catastrophic failure.

In addition to internal porosity, if this is present on a sealing surface of a component, it can prevent proper sealing, leading to leaks and potentially dangerous situations.

  1. Surface Cracks

Surface cracks are fractures that appear on the exterior of a component. In applications involving cyclic loading, such as turbine blades or engine components, surface cracks can lead to fatigue failure. Over time, these cracks propagate and grow, eventually causing the part to break. In a heat exchanger, surface cracks in the core can compromise the integrity of cooling channels, leading to insufficient heat dissipation and overheating.

  1. Volumetric Cracks

Volumetric cracks are internal cracks that are not visible on the surface. These cracks require loading and repeated stress to expand, but if left undetected, they pose a high risk of part failure. For example, in critical aerospace components, hidden volumetric cracks can lead to sudden and catastrophic failure under operational stresses. In aero engine and turbine blades, volumetric cracks can also be creep initiation sites that, under thermal cycling inherent in the application weaken the blade without any visible sign until failure occurs.

  1. Voids

Voids are spherical pores within the material that create areas of weakness. Components with voids are more susceptible to failure under pressure or mechanical stress as the local area is mechanically less stiff. In safety-critical applications like medical implants or structural aerospace parts, the presence of voids can compromise the part’s strength and reliability.

  1. Delamination

Delamination occurs when layers within a component separate, creating weak points. This is particularly concerning for metal AM parts subjected to tension. For instance, in a tensioned fixture that is bolted at both ends, delamination can lead to a failure of the connection, compromising the overall structural integrity.

Detailed close-up of an additive manufactured metal bar.

An SEM image of a crack in an ASTM coupon.

 

The consequences of leaving flaws undetected

It goes without saying that failing to identify and address flaws within additive manufactured parts can have severe consequences, especially when manufacturing for safety-critical applications. If effective procedures for flaw identification are not used, undetected defects can lead to:

Catastrophic Failure:

In aerospace or automotive applications, a failure due to a hidden defect can result in accidents, endangering lives and causing significant financial losses.

Reduced Lifespan:

Flaws such as porosity or cracks can shorten the lifespan of components, leading to premature failure and the need for costly replacements.

Operational Inefficiency:

Defective parts can cause systems to operate inefficiently, increasing energy consumption and operational costs.

Safety Hazards:

In medical or power generation applications, defects can pose serious safety risks, potentially leading to harmful situations.

additive manufactured parts covered in metal powder

The role of nonlinear resonance NDT in AM flaw detection

Traditional non-destructive testing (NDT) methods, such as X-ray Computed Tomography (X-CT) scans, have limitations in terms of sensitivity, speed, and cost. Nonlinear Resonance NDT (NLR NDT) offers a superior alternative for detecting the presence of flaws in additive manufactured parts. Here’s how NLR NDT addresses the challenges of traditional methods:

High Sensitivity:

Nonlinear resonance can detect smaller defects than other NDT techniques, ensuring that even the most minute flaws are identified before they can cause problems.

Rapid Testing:

Nonlinear resonance NDT can deliver results in under a minute, significantly faster than the two-hour process required for X-ray CT. This rapid testing allows for real-time quality control and immediate identification of defects.

Cost-Effective:

Nonlinear resonance NDT is more cost-effective than traditional part inspection methods. It allows for the testing of parts immediately after printing, preventing the addition of unnecessary value to defective components by proceeding onto those all-important post-processing steps. This leads to reduced cost per part and a much faster return on your investment.

Versatility:

Nonlinear resonance NDT can be used on parts with complex shapes and surface finishes, making it ideal for the varied geometries achievable through additive manufacturing. It can also be deployed at various stages of the manufacturing process, including post-processing, to ensure comprehensive quality control from start to finish.

Final thoughts

Ensuring the integrity and reliability of additive-manufactured parts is crucial, especially for safety-critical applications. By understanding the different types of flaws that can occur and the severe consequences of leaving them undetected, manufacturers can take proactive steps to improve their processes and implement effective inspection methods.

Theta Technologies’ Nonlinear Resonance NDT offers a powerful solution for identifying defects where other NDT techniques may fall short, providing the sensitivity, speed, and cost-effectiveness needed to maintain the highest quality standards in additive manufacturing.

Discover the applications by

exploring our case study library.

From automotive heat exchangers to aerospace hinge brackets, see how nonlinear resonance NDT performs when put to the test for a range of additive manufactured components.

Innovators in

Non-Destructive Testing Technology

Our patented nonlinear resonance non-destructive testing technology is pushing the boundaries of what is possible with AM part qualification. The versatility and adoption of 3D printing as a viable manufacturing technology creates unique part inspection challenges that are holding back industry adoption. Our unique solution has been meticulously developed to combat the challenges faced by additive manufacturers and the widespread deployment of AM parts for safety-critical applications.

Providers Of The World’s Only

Nonlinear Resonance NDT solution

Our first commercially packaged embodiment of our unique non-destructive testing technology, RD1-TT, fits seamlessly into your existing manufacturing workflow. Now you can experience the power and versatility of nonlinear resonance NDT in your very own production environment to facilitate faster, more regular and cost-effective part inspection.

Educators in

Non-Destructive Testing

We believe that education is the lifeblood of any successful business. Having started our journey as a spinout of Exeter University, education is a fundamental part of our own development. You’ve engineered your parts, you’ve optimised your production process, now let us guide you through the field of part inspection and non-destructive testing.

Talk to

Our Team of

Technical Specialists

Connect with our team of technical experts today and explore how RD1-TT can help revolutionise your additive manufacturing processes.

Theta Technologies Limited

Information

Address

Theta Technologies Limited

3 Babbage Way

Exeter Science Park

Clyst Honiton

Exeter

EX5 2FN

United Kingdom

Contact

Enquiries: +44(0)1392 247912

Email: info@thetandt.com

 

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