What tests verify quality and performance of WAAM-printed titanium alloys?

Tests That Verify Quality and Performance of WAAM-Printed Titanium Alloys

To ensure that WAAM-printed titanium alloys—such as Ti-6Al-4V—meet aerospace-grade performance, a combination of non-destructive and destructive tests is applied. Non-destructive testing (NDT) methods such as X-ray, CT scanning and ultrasonic testing are used to detect porosity, lack of fusion and internal defects without damaging the part. Dye penetrant testing is also utilized to locate surface cracks and verify layer bonding consistency.

To validate mechanical properties, tensile, hardness and fatigue testing are performed to assess strength, ductility and long-term performance under cyclic loading. These tests are often followed by post-process treatments such as HIP or heat treatment to ensure full densification and microstructural stability.

Material Characterization and Validation

Metallographic examination is essential for evaluating grain structure, heat-affected zones and potential phase transformation. Advanced material testing and analysis techniques—such as SEM/EDS and chemical composition analysis—ensure that titanium alloys conform to aerospace specifications. Creep, fracture toughness and stress-corrosion testing are also performed when components are intended for high-pressure or thermal environments.

Together, these testing methods ensure that WAAM-printed titanium parts deliver consistent quality, structural reliability and performance comparable to conventionally manufactured aerospace components.