Establishment of X-ray computed tomography traceability for additively manufactured surface texture evaluation

Metal additively-manufactured (AM) parts are increasingly used as safety-critical components in industry. Surface textures of metal AM parts are different to conventionally machined surfaces and can directly influence the functional performance of the parts. However, it is difficult or impossible to access and measure non-line-of-sight AM surfaces by conventional measurement techniques. X-ray computed tomography (XCT) is a promising technique that can measure non-line-of-sight surfaces non-destructively. However, the metrology framework for XCT to evaluate surface texture of AM parts is yet to be fully established, and there is a lack of development in surface texture reference standards that fit the purpose.

In this paper, we have established a route to calibrate XCT for AM surface texture evaluation using a prototype three-dimensional roughness standard (3DRS) developed by the National Physical Laboratory that has a range of AM surface texture features and was designed for compatibility between 2D (profile), 2½D (areal), and tomography measuring instruments. A measurement protocol has been established between XCT and the contact stylus system, and uncertainty evaluation of 3DRS surface texture was established.