Journal
MEASUREMENT SCIENCE AND TECHNOLOGY
Volume 33, Issue 8, Pages -Publisher
IOP Publishing Ltd
DOI: 10.1088/1361-6501/ac6397
Keywords
dimensional metrology; surface topography; performance verification; additive manufacturing; calibration; roughness standard
Funding
- UK Government's Department for Business, Energy and Industrial Strategy (BEIS) through the UK's National Measurement System programme
- European Association of National Metrology Institutes (EURAMET) Joint Research Project [17IND08 AdvanCT]
- EMPIR programme - European Union
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The complex topography of additively-manufactured surfaces and the rapid evolution of measurement instruments have led to a lack of trust in inspection data. To improve confidence in measurement, a surface texture measurement standard has been designed and calibrated.
The unique complex topography of additively-manufactured surfaces-and the recent rapid evolution of instruments and techniques to measure them-limits trust in inspection data, in direct conflict with the requirements of application areas such as aerospace, where failure of a part can have serious safety consequences. Topography instrument manufacturers and end-users require measurement standards with a controlled reproduction of representative additively-manufactured surfaces to calibrate, performance-verify and intercompare instruments for inspection tasks, thereby improving confidence in measurement. The design of such a surface texture measurement standard is reported, optimised for optical areal topography-measuring instruments and compatible with x-ray computed tomography instruments. Machined from an additively-manufactured blank, the standard's four sides represent increasing levels of post-processing from the as-deposited surface. Datum features on the measurement standard facilitate direct comparison between topography instruments. Integrated step features support the calibration of an instrument's Z scale. Calibration of a prototype of the standard is reported; the prototype is matched to a typical aerospace Scalmalloy (TM) additive manufacturing process. The calibration is also a trial application of a large-area chromatic confocal microscope; this instrument appears capable of calibrating relatively rough measurement standards if required to do so. Reference Ra and S-parameter measurements and associated measurement uncertainties are presented, correlation between parameters noted, and choice and consequences of filter settings discussed.
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