SYMPOSIA PAPER Published: 05 June 2020
STP162020180106

NDE-Based Quality Assurance of Metal Additively Manufactured Aerospace Parts at NASA, JAXA, and ESA

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As metal additive manufactured spaceflight hardware moves closer to use in upcoming missions, the need for appropriate nondestructive evaluation (NDE) procedures to qualify and certify parts becomes more pressing. Traditionally, the level and specificity of certification requirements for aerospace parts is linked to part criticality, which is determined by structural margin, consequence of failure, and part inspectability. Unfortunately, rule-level (performance-based) certification requirements often do not define specific or acceptable NDE procedures or requirements. This level of detail usually falls on the original equipment manufacturer (OEM), which is unwise in the case of new technology, such as additive manufacturing (AM). Instead, it is incumbent upon the end user to communicate risks and with the OEM and to provide oversight to ensure risks are controlled. These risks arise from many sources, including uncertainty about property optimization for rapidly evolving AM processes, lack of engineering experience, and limited operational histories. From the NDE perspective, the main risk arises from uncertainty in the NDE procedure to detect the requisite critical flaw type, size, and distribution. Because the level of criticality of AM aerospace parts is expected to increase, more effort is needed to characterize and understand fatigue and fracture properties of AM materials. Crack initiation resulting from the presence of AM flaws must be considered. This requires knowledge of the critical initial flaw size (CIFS) and the appropriateness of NASA-STD-5009 flaw sizes. Knowledge of the CIFS for a given AM flaw type will allow for the fracture control and NDE communities to evaluate risks and communicate recommendations regarding the acceptability of risk. Toward this goal, this paper discusses NDE-related activities at the National Aeronautics and Space Administration, Japan Space Exploration Agency, and European Space Agency. Current NDE best practices for AM hardware are discussed, along with tailoring NDE according to part criticality.

Author Information

Waller, Jess, M.
NASA-Johnson Space Center White Sands Test Facility, Las Cruces, NM, US
Burke, Eric, R.
NASA Langley Research Center, Langley, VA, US
Wells, Douglas, N.
NASA Marshall Space and Flight Center, Huntsville, AL, US
Nichols, Charles, T.
NASA-Johnson Space Center White Sands Test Facility, Las Cruces, NM, US
Brandão, Ana, D.
ESA/ESTEC, European Space Research and Technology Center, Noordwijk, NL
Gumpinger, Johannes
ESA/ESTEC, European Space Research and Technology Center, Noordwijk, NL
Born, Martin
ESA/ESTEC, European Space Research and Technology Center, Noordwijk, NL
Ghidini, Tommaso
ESA/ESTEC, European Space Research and Technology Center, Noordwijk, NL
Nakagawa, Tsuyoshi
Japanese Aerospace Exploration Agency, Tsukuba, Ibaraki, JP
Koike, Akio
Japanese Aerospace Exploration Agency, Tsukuba, Ibaraki, JP
Mitsui, Masami
Japan Quality Assurance Organization, Tokyo, JP
Itoh, Tsuyoshi
Japanese Aerospace Exploration Agency, Tsukuba, Ibaraki, JP
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Developed by Committee: F42
Pages: 92–129
DOI: 10.1520/STP162020180106
ISBN-EB: 978-0-8031-7687-4
ISBN-13: 978-0-8031-7686-7