Overview
ISO/ASTM TR 52906:2022 - Additive manufacturing - Non-destructive testing - Intentionally seeding flaws in metallic parts - is a technical report that provides best-practice guidance for intentionally creating (seeding) nondestructively detectable flaw replicas in metallic parts made by Powder Bed Fusion (PBF) and Directed Energy Deposition (DED). The report describes three primary seeding approaches: CAD-based seeding, build-parameter manipulation, and subtractive (post-production) manufacturing. It covers replicas in as‑deposited, post‑heat‑treated, and HIP‑processed materials and focuses on creating representative flaws for NDT/NDE (XCT, radiography, ultrasonic, etc.) validation and capability demonstrations.
Key topics and technical requirements
- Seeding categories:
- CAD seeding (designing flaws into the model),
- AM process manipulation (altering parameters to produce pores, keyholes, trapped powder, inclusions),
- Post-production mechanical or thermal methods (machining, EDM, laser drilling).
- Flaw types addressed: pores, keyhole porosity, trapped/unsintered powder, inclusions, lack of fusion (layer and cross-layer), layer shift, cracking and other porosity/void morphologies. Note: intimate “kissing” bonds are out of scope.
- Material and process scope: metallic alloys produced by L‑PBF, EB‑PBF, L‑DED, GMA‑DED, EB‑DED and similar technologies; covers as‑built and post‑processed (heat‑treated, HIP) conditions.
- NDT considerations: guidance to create replicas that match the physical morphology and NDT response (radiographic, XCT, ultrasonic) so labs can assess detection sensitivity and inspection reliability.
- Limitations & safety: geometric metrology is not covered; users must establish appropriate safety and regulatory controls.
Practical applications - who should use this standard
- NDT/NDE laboratories - design and validate inspection procedures, calibrate equipment, and quantify detection limits for AM parts.
- AM engineers & OEMs (aerospace, medical, energy) - create Representative Quality Indicators (RQIs) and test coupons for process validation and production inspection plans.
- Quality & regulatory teams - demonstrate capability and traceability of NDT methods for certification and supplier qualification.
- Standards developers & researchers - harmonize flaw replication techniques and compare NDT modality performance on AM alloys.
Related standards
- ISO/ASTM TR 52905 (AM flaw classification)
- ISO/ASTM 52900 (AM terminology)
- ISO 17296-2 (AM process descriptions)
- ASTM E1817 (Representative Quality Indicators)
- ASTM B243, ASTM E7, ASTM E1316 (terminology and metallography/NDE references)
Keywords: ISO/ASTM TR 52906:2022, additive manufacturing, non‑destructive testing, NDT, flaw seeding, PBF, DED, replicas, porosity, XCT, radiography, ultrasonic, quality assurance.