Common testing methods to ensure quality of LENS-printed high-temperature alloy parts
Non-Destructive Evaluation (NDE)
Because LENS-printed high-temperature alloys may contain internal porosity or residual stress, advanced NDE techniques are applied before any post-processing begins. X-ray and CT scanning detect internal voids, while ultrasonic testing verifies bonding continuity between deposited layers. These inspections are typically paired with material testing and analysis to evaluate structural integrity without damaging the part.
Mechanical Property Testing
Mechanical tests determine the performance of LENS-produced alloys under real operating conditions. Tensile tests, fatigue life assessment, creep evaluation, and hardness measurements are performed to validate mechanical stability. After heat treatment or HIP densification, properties can match or exceed forged materials, particularly in nickel-based superalloys such as Inconel 718.
Metallographic Examination
Microscopic inspection of cross-sections is performed to analyze grain structure, fusion quality, and phase distribution. Metallographic analysis reveals the effectiveness of heat treatment in refining microstructure and reducing anisotropy. Grain boundary conditions are crucial for alloys used in power generation and aerospace applications.
Dimensional Inspection and Surface Analysis
After CNC finishing, dimensional checks using CMM (Coordinate Measuring Machine) and 3D scanning verify tolerance accuracy. Surface profile measurement ensures that sealing surfaces and assembly interfaces meet specifications. Precision finishing via superalloy CNC machining restores dimensional consistency before final assembly.
Application-Level Validation
For critical rotating and high-pressure systems, functional testing under simulated operating environments is essential. Temperature cycling, pressure testing, and stress load simulation replicate real-world conditions. These validation procedures are widely applied across oil and gas and military and defense sectors, ensuring long-term reliability and fatigue resistance.
