New Case Study | HIGH-ENERGY CT SCAN ON INCONEL 718 HEAT EXCHANGER Analysis and Commentary on a High-Energy CT Scan

Non-destructive testing (NDT) is essential in additive manufacturing, safeguarding the quality, reliability, and safety of components without inflicting any harm. In this case study, we collaborated with AddUp, a leading global metal additive manufacturing OEM. AddUp supplied a 3D-printed heat exchanger to demonstrate the advantages of high-energy CT scanning.

This heat exchanger, tailored for the aeronautical sector, functions as a pre-cooler. It efficiently cools hot air extracted directly from an airliner's turboengines. Crafted from Inconel 718, the exchanger withstands temperatures exceeding 300°C, showcasing its robustness for high-temperature applications. It was manufactured using AddUp’s FormUp 350 Powder Bed Fusion (PBF) machine. The machine’s quad laser system excels in crafting fine features with unparalleled quality and productivity. Utilizing four lasers simultaneously enhanced the manufacturing speed. The heat exchanger features wall thicknesses (fins) ranging from 100 to 300μm and a surface finish (on the fins and channels) below 6μm, ensuring optimal airflow and thermal exchange for maximum heat transfer efficiency.

In preparing this case study, AddUp intentionally introduced several defects into the inner fins of the heat exchanger. Inconel's high density and unique material properties make it challenging to CT scan. However, the high-energy CT scanning with the DIONDO LINAC D7 – 6.0 MeV Tomograph successfully detected these defects without causing any damage to the component.

This case study illustrates the crucial role of NDT in additive manufacturing. It underscores the importance of maintaining high standards of quality and safety while optimizing manufacturing processes. This contributes significantly to the success and broader adoption of this cutting-edge manufacturing technology.

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