Erin Lanigan

Date of Award


Document Type


Degree Name

Master of Science in Engineering (MSE)


Mechanical and Aerospace Engineering

Committee Chair

Judy Schneider

Committee Member

Gang Wang

Committee Member

George Nelson


Additive manufacturing, Nondestructive testing, Tomography


Monitoring systems developed for laser powder bed fusion (LPBF) metal additive manufacturing (AM) can be useful in qualifying parts. Aerospace applications often require nondestructive evaluation (NDE) as part of a damage tolerance approach. However, AM poses a challenge for NDE due to the typical part size and complexity. In situ monitoring can potentially take advantage of the layer-wise manufacturing process to inspect the part as it is built. This requires correlating indications in the monitoring data with the formation of flaws in the finished part. To develop this correlation, LPBF samples were made with seeded voids. Destructive serial sectioning metallography was used to provide ground truth flaw characterization. The resolution capability of in situ monitoring was compared to the typical NDE method, computed tomography (CT). In situ monitoring was able to detect the presence of voids that were below the detection limit of CT but observable using serial sectioning metallography.



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