# US 12,599,967 B2 · Non-destructive testing method for LOF defects, and a testing standard part and manufacturing method therefor

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- Number: US 12,599,967 B2
- Document ID: US12599967B2
- Status: Granted
- Kind: B2
- Application number: 17/920,572
- Filed: 2020-12-28
- Published: 2023-05-25
- Granted: 2026-04-14
- Earliest claimed: 2020-04-22
- Assignees: Aecc Shanghai Commercial Aircraft Engine Manufacturing Co., Ltd.; Aecc Commercial Aircraft Engine Co., Ltd.
- Applicants: Aecc Shanghai Commercial Aircraft Engine Manufacturing Co., Ltd.; Aecc Commercial Aircraft Engine Co., Ltd.
- Inventors: Yali Li; Liming Lei; Jun Fu; Yanli He; Yinlan Zheng
- Web page: https://patentgrep.com/patent/US12599967B2

## CPC

- B22F 10/28: Powder bed fusion, e.g. selective laser melting [SLM] or electron beam melting [EBM]
- B22F 10/36: of energy beam parameters
- B22F 10/366: Scanning parameters, e.g. hatch distance or scanning strategy
- B22F 10/38: to achieve specific product aspects, e.g. surface smoothness, density, porosity or hollow structures
- B22F 10/85: for controlling or regulating additive manufacturing processes
- B22F 12/90: Means for process control, e.g. cameras or sensors
- B33Y 10/00: Processes of additive manufacturing
- B33Y 50/02: for controlling or regulating additive manufacturing processes
- Y02P 10/25: Process efficiency
- B22F: WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER (making alloys by powder metallurgy C22C); APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B33Y: ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
- Y02P: CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS

## Abstract

A non-destructive testing method for lack-of-fusion (LOF) defects, and a testing standard part and a manufacturing method thereof, used for the non-destructive testing of LOF defects of an additive manufacturing workpiece. The manufacturing method of the LOF defect standard part comprises: step A, setting a LOF defect area of the standard part, in the LOF defect area, a proportion of the LOF defects in the LOF defect area is set as a first proportion value; step B, selecting an additive manufacturing forming process for manufacturing the LOF defect area to obtain a first process parameter of the additive manufacturing forming process corresponding to the first proportion value; step C, performing the additive manufacturing forming process based on the first process parameter to form the LOF defect area.

## Claims

### Claim 1

A manufacturing method of a LOF defect standard part, used for non-destructive testing of LOF defects of an additive manufacturing workpiece, comprises:
step A, setting a LOF defect area of the standard part, wherein in the LOF defect area, a proportion of the LOF defect area is occupied by LOF defects, wherein setting the LOF defect area of the standard part comprises setting, as a first proportion value, the proportion of the LOF defect area that is occupied by LOF defects, wherein step A further comprises setting a body area of the standard part, wherein the body area is free of LOF defects;
step B, selecting an additive manufacturing forming process for manufacturing the LOF defect area to obtain a first process parameter of the additive manufacturing forming process corresponding to the first proportion value, and selecting another additive manufacturing forming process for manufacturing the body area to obtain a second process parameter of the another additive manufacturing forming process corresponding to the body area; and
step C, performing the additive manufacturing forming process based on the first process parameter to form the LOF defect area, and performing the another additive manufacturing forming process based on the second process parameter to form the body area;
wherein, the additive manufacturing forming process is a laser selective melting forming process, the material in the LOF defect area is Hastelloy X alloy, the first proportion value is 0.4%-5.7%, the first process parameter comprises: a first laser linear energy density of 66 J/m-113 J/m, a first scanning spacing of 0.10 mm-0.12 mm, a first strip width of 7 mm-10 mm, a first strip overlap of 0. mm-0.05 mm, and a first paving powder thickness of 0.02 mm-0.03 mm, the first laser linear energy density is determined by the following formula:
a
=
753.27
e
-
η
13.4
+
0.19
wherein a is the first proportion value, and n is the first laser linear energy density.

### Claim 2 (depends on 1)

The manufacturing method of claim 1, wherein in the step B, the first proportion value is 5.7%, the first laser linear energy density is 66 J/m, the first scanning spacing is 0.12 mm, the first strip width is 10 mm, the first strip overlap is 0 mm, and the first paving powder thickness is 0.03 mm; or
in the step B, the first proportion value is 0.4%, the first laser linear energy density is 113 J/m, the first scanning spacing is 0.1 mm, the first strip width is 7 mm, the first strip overlap is 0.05 mm, and the first paving powder thickness is 0.03 mm; or
in the step B, the first proportion value is 1.7%, the first laser linear energy density is 82 J/m, the first scanning spacing is 0.11 mm, the first strip width is 9 mm, the first strip overlap is 0.03 mm, and the first paving powder thickness is 0.03 mm.

### Claim 3 (depends on 1)

The manufacturing method of claim 1, wherein in the step B, the another additive manufacturing forming process is a laser selective melting forming process, the material in the body area is Hastelloy X alloy, and the second process parameter of the another additive manufacturing forming process comprises: a second laser linear energy density of 170 J/m-200 J/m, a second scanning spacing of 0.08 mm-0.10 mm, a second strip width of 4 mm-6 mm, a second strip overlap of 0.06 mm-0.1 mm, and a second paving powder thickness of 0.02 mm-0.03 mm.

### Claim 4 (depends on 1)

A non-destructive testing method for LOF defects, used for testing LOF defects of an additive manufacturing workpiece, comprises:
step 1, manufacturing the standard part according to the manufacturing method of claim 1, and performing non-destructive testing on the standard part, obtaining a calibration testing signal of the non-destructive testing of the LOF defects of the standard part, to determine a testing parameter of the non-destructive testing; and
step 2, performing the non-destructive testing on the additive manufacturing workpiece, according to the testing parameter obtained in the step 1, to obtain an experiment testing signal of the additive manufacturing workpiece, and obtaining a LOF defect proportion of the additive manufacturing workpiece according to the experiment testing signal.

### Claim 5 (depends on 4)

The testing method of claim 4, further comprising:
step 3, performing a mechanical test on the additive manufacturing workpiece to obtain a mechanical property of the additive manufacturing workpiece and relationship between the LOF defect proportion and the mechanical property.

### Claim 6 (depends on 4)

The testing method of claim 4, wherein the step 1 comprises:
performing the non-destructive testing to obtain the calibration testing signal of the non-destructive testing of the LOF defects of the standard part to determine the testing parameter of the non-destructive testing.