What testing methods ensure the quality of LENS 3D-printed Ti-6Al-4V parts?

Non-Destructive Evaluation (NDE)

To verify the structural integrity of LENS 3D-printed Ti-6Al-4V parts without damaging them, non-destructive testing is crucial. Techniques such as X-ray inspection and CT scanning detect internal porosity and lack-of-fusion defects. For aerospace-grade reliability, ultrasonic testing is also applied to verify bond quality and layer continuity before advanced post-processing. These methods are commonly used alongside material testing and analysis procedures.

Mechanical Property Validation

After deposition and heat treatment, mechanical tests such as tensile strength, fatigue life, and hardness measurements are performed to evaluate performance. Stress-corrosion and creep resistance are assessed to confirm suitability for aerospace and aviation or energy applications. The combination of solution treatment, aging, and optional hot isostatic pressing (HIP) is validated through stress-relief and densification performance metrics.

Metallographic Analysis

To confirm phase stability and grain structure, metallographic examination is conducted after polishing and etching the sample. This analysis verifies layer fusion quality and microstructural homogeneity. It also confirms the absence of inconsistent grain boundaries or heat-affected zones that can reduce fatigue life.

Dimensional and Surface Inspection

Following densification and machining, precision measurements using CMM (Coordinate Measuring Machine) and surface profilometry are applied to verify tolerance compliance. Processes such as CNC machining ensure dimensional recovery, while surface roughness analysis evaluates suitability for sealing or assembly interfaces.

Application-Level Validation

For high-stress sectors like oil and gas and military and defense, full-scale validation is often required. Functional testing under simulated operating conditions ensures long-term durability and resistance to fatigue. Combining testing with post-process treatments, such as heat treatment and HIP, enables Ti-6Al-4V to achieve aerospace-grade reliability.