On the use of reference measurements to improve the accuracy of tomographic porosity analysis in laser powder bed fusion metal parts

Laser powder bed fusion of metals (PBF-LB/M) enables the production of complex parts with innovative designs. However, porosity formation poses significant challenges to structural integrity, making reliable measurement of internal defects vital for ensuring part quality. While X-ray computed tomography (CT) offers holistic non-destructive analyses of internal features, establishing metrological traceability in CT-based porosity measurements is crucial for robust quality control and process optimization. This is especially important for PBF-LB/M components, where typical defects are irregularly shaped and often contain entrapped powder particles. This study investigates a novel approach to improve the accuracy of porosity analysis in PBF-LB/M components by leveraging reference porosity measurements. The proposed approach combes multi-view optical profilometry and X-ray CT for defect calibration, providing a foundation for enhancing CT porosity analysis and advancing quality assurance in additive manufacturing of metal parts.