Quality assurance in laser-based, metal additive manufacturing: Generation and detection of systematics and stochastic defects
Laser-based powder bed fusion (PBF) and directed energy deposition (DED) additive manufacturing have been embraced by much of the aerospace and defense industry for part production and repair. Unfortunately, there still remains considerable uncertainty regarding the causes and effects of many defects types observed in PBF and DED components. Numerous conditions can lead to the formation of defects (i.e. internal discontinuities or undesirable microstructure) that can negatively affect build and part quality. Some of these defects are easily attributable to systematic errors (e.g.