About this Abstract |
| Meeting |
2026 Annual International Solid Freeform Fabrication Symposium (SFF Symp 2026)
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| Symposium
|
2026 Annual International Solid Freeform Fabrication Symposium (SFF Symp 2026)
|
| Presentation Title |
Defect-Oriented PFMEA Consolidation and Monitoring-Opportunity Framework for Quality Assurance in Laser Powder Bed Fusion |
| Author(s) |
Ashish Gahlot, Tobias Karl, Martin Bach, Matthias Merzkirch, Markus G.R. Sause |
| On-Site Speaker (Planned) |
Ashish Gahlot |
| Abstract Scope |
Quality Assurance (QA) for Laser Powder Bed Fusion (LPBF) must address defects that may originate or change across the complete manufacturing route. Process Failure Mode and Effects Analysis (PFMEA) records process-specific causes and controls, but repeated terminology makes route-level tracking difficult. This study converts a validated 696-row PFMEA covering ten manufacturing/post-processing steps and three verification steps into a traceable Defect Detection Matrix (DDM) for a Ti-6Al-4V route. Screening identified 514 physical-defect-related rows, producing 703 links and eight consolidated defect types. Each manufacturing and post-processing step was reviewed by a process expert. The DDM records contributing conditions, origins, modification, exposure or reduction, verification, and earlier QA opportunities. The results show two route patterns: lack of fusion and porosity have concentrated origins around LPBF, whereas the remaining defect types can originate or change at multiple stages. The outcome is a basis for positioning QA closer to defect-generating operations while retaining downstream verification. |
| Proceedings Inclusion? |
Planned: Post-meeting proceedings |