Overview
Implementation challenges of metallic AM parts in load carrying structures prevent small OEM to take the risks to adapt this novel technology and to use the full capacity of its advantages. Risks in terms of operational reliability and unknown qualification costs are often considered as too high and prevent innovative design solutions.The structural integrity of AM components is addressed by developing efficient methodologies for defect tolerant structural substantiation and associated requirements for qualification testing. Fracture mechanics based modelling combined with probabilistic description of the inherent material flaw distributions are employed to address the risks of failure. Manufacturing driven variability of material parameters need to be considered in the framework of structural substantiation, qualification testing, non-destructive testing and applicable quality acceptance criteria. Practical structural integrity concepts are considered as prerequisite to closely optimize loaded AM component by e.g. topology optimization and for a successful introduction in the field.
