Progressive damage and failure analysis of metal parts using computed tomography

A computer system comprising:

• a processor;
• and
• a computer readable storage medium on which is recorded an instruction set executable by the processor, wherein executing the instruction set causes the processor to:
• receive Computed Tomography (CT) image data of a metal test component;
• process the CT image data via the processor to thereby detect observable defects in the metal test component;
• characterize the observable defects into a plurality of corresponding defect categories;
• generate a data table of the observable defects and the corresponding defect categories;
• embed a collective set of data from the data table into a finite element model (FEM) of the metal test component to thereby construct a modified FEM of the metal test component;
• analyze the modified FEM through an isotropic and/or anisotropic structural model, via the processor, to thereby generate a set of test results;
• and
• execute a quality control action with respect to the metal test component based on the set of test results.

A computer-based method for evaluating progressive damage in a three-dimensional (3D)-printed metal part, comprising:

• providing Computed Tomography (CT) image data of the 3D-printed metal part to a processor;
• processing the CT image data via the processor, including detecting observable defects in the 3D-printed metal part;
• characterizing the observable defects into a plurality of corresponding defect categories, including constructing a registry of distributions of locations, sizes, and shapes of the observable defects;
• generating a data table of the observable defects and the corresponding defect categories;
• embedding a collective set of data from the data table into a finite element model (FEM) of the 3D-printed metal part to thereby construct a modified FEM of the 3D-printed metal part;
• analyzing the modified FEM through an isotropic and/or anisotropic structural model, via the processor, to thereby generate a set of test results, including using one or more of an isotropic elastic model, an isotropic plasticity model, or anisotropic plasticity model;
• and
• executing a quality control action with respect to the 3D-printed part based on the set of test results.