Quality Assessment of Selective Laser Melting Components Using Quantitative Ultrasound Measurements and Image Texture Analysis

Successful production of metallic selective laser melting components requires a quality assurance process that can effectively and nondestructively assess internal defects. Ultrasound testing has emerged as a valuable modality for defect identification as well as the characterization of microstructural and material properties. In this study, a comprehensive quality assessment approach was developed, leveraging quantitative ultrasound parameters, images, and image texture analysis. The evaluation focused on Inconel 718 selective laser melting components manufactured using diverse combinations of process parameters. The investigation involved examining the correlation between ultrasound parameters, image texture features, and the overall quality of the fabricated components. To validate the findings obtained through ultrasound testing, micro-computed tomography was employed. The experimental results provided evidence that the ultrasound parameters and image texture features successfully detected nonhomogeneous microstructures present within the selective laser melting components. Notably, the speed of sound and attenuation exhibited a positive correlation of 0.64 and 0.74, respectively, with porosity, indicating their potential as indicators of porosity. Furthermore, image texture features such as entropy, contrast, and homogeneity demonstrated high correlations (
$R^{2}\gt 0.7$
) with the quality of the components. Consequently, these identified features hold promising potential for aiding in the selection of optimal process parameters and the prediction of porosity in future research.