How Does Non-Destructive Testing Verify Corrax WAAM Component Quality?

Liquid Penetrant Testing for Surface Defect Detection

Liquid penetrant testing (LPT) serves as the primary surface examination method for Corrax WAAM components, effectively identifying surface-breaking defects such as micro-cracks, lack-of-fusion zones, and porosity. The testing process capitalizes on Corrax's non-porous martensitic structure after proper precipitation hardening treatment, allowing penetrant fluids to highlight even minute surface discontinuities that could compromise performance in demanding applications. This method is particularly crucial for components destined for aerospace tooling or injection molding applications where surface integrity directly affects performance.

Ultrasonic Testing for Internal Integrity Assessment

Ultrasonic testing (UT) provides comprehensive internal quality verification for Corrax WAAM components, detecting subsurface defects including lack-of-fusion between deposition layers, internal porosity, and inclusion clusters. Using phased array ultrasonic technology with specialized transducers and coupling fluids optimized for maraging stainless steels, inspectors can map internal structures with high resolution. The technique is particularly effective for verifying the success of Hot Isostatic Pressing (HIP) treatments by confirming the elimination of internal voids and ensuring homogeneous material density throughout the component.

Eddy Current Testing for Near-Surface Evaluation

Eddy current testing offers sensitive near-surface defect detection and material characterization for Corrax components. This electromagnetic method identifies surface and slightly subsurface flaws while simultaneously verifying heat treatment consistency by detecting variations in electrical conductivity that correlate with improper aging treatment. The technique is exceptionally valuable for complex geometries and hard-to-reach areas where visual inspection is limited, providing rapid scanning capabilities that complement other NDT methods while ensuring the precipitation hardening has achieved uniform mechanical properties.

Industrial CT Scanning for Complex Internal Geometries

For Corrax WAAM components with intricate internal features or complex geometries, industrial computed tomography (CT) scanning provides comprehensive 3D volumetric data of both external and internal structures. This advanced method detects internal defects, verifies dimensional accuracy, and confirms the integrity of internal channels or cooling passages often incorporated into tooling components. While more expensive than other methods, CT scanning offers unparalleled insight into component quality, making it invaluable for mission-critical applications where failure is not an option.

Quality Correlation and Process Validation

The various NDT methods work synergistically to provide comprehensive quality assurance, with results correlated to validate findings across different inspection modalities. This multi-method approach not only identifies defects but also provides data for process optimization, helping manufacturers refine WAAM parameters for Corrax deposition. All inspection results are documented alongside material certification data to provide complete traceability and quality verification for clients in high-stakes industries where component reliability is paramount.