Defects in Metal Additive Manufacturing Processes

The formation of defects within additive-manufactured (AM) components is a major concern for critical structural and cyclic load applications. Thus, understanding the mechanisms defect in fusion-based processes important prescribing appropriate process parameters specific to alloy system selected processing technique. This article discusses metal additive manufacturing, namely solid-state/sintering processes. Defects observed include lack fusion, keyhole collapse, gas porosity, solidification cracking, solid-state surface-connected porosity. types are sintering porosity improper binder burnout. also defect-mitigation strategies, such as postprocess machining, surface treatment, postprocessing HIP, eliminate detrimental properties from as-built condition. use noncontact thermal, optical, ultrasound techniques inspecting AM considered. final section summarizes knowledge gap our components.