X-ray computed tomography dimensional measurements of powder bed fusion cellular structures

Metal parts with controlled cellular structures can be produced via additive manufacturing technologies. However, critical aspects of additively manufactured products include poor geometrical accuracy and complex surface morphology, which can lead to mechanical properties degradation and product failure. To control and improve these aspects, X-ray computed tomography can be applied, enabling advanced three-dimensional non-destructive evaluations of both external and non-accessible features. In this work, Ti6Al4V cellular structures with different periodic lattice designs produced by powder bed fusion were analysed using a metrological X-ray computed tomography system. In particular, challenges and accuracy of CAD comparison and thickness analyses were studied through specific experimental and simulation investigations, taking into account also the influence of structural distortions and surface morphology.