LR and TWI Guidance Notes For Additive Manufacturing Jan2016

Guidance Notes
for
Additive Manufacturing
of Metallic Parts
January 2016
Guidance Notes
for
of Metallic Parts

January 2016
Guidance Notes for Additive Manufacturing of Metallic Parts, January 2016
Guidance Notes for

of Metallic Parts
These Guidance Notes are intended to be a live document and
are subject to change without notice.
A comprehensive list of Contents is placed at the beginning of
these Notes.
Lloyds Register Group Limited, its subsidiaries and affiliates and their respective officers, employees or agents are, individually and collectively, referred to in this clause
as Lloyds Register. Lloyds Register and TWI Ltd assume no responsibility and shall not be liable to any person for any loss, damage or expense caused by reliance on the
information or advice in this document or howsoever provided, unless that person has signed a contract with the relevant Lloyds Register entity and TWI Ltd for the provision
of this information or advice and in that case any responsibility or liability is exclusively on the terms and conditions set out in that contract.
Lloyds Register and TWI
Contents
Contents
Additive Manufacturing of Metallic Parts

Section
Introduction
Abbreviations and Definitions
Suitability for Additive Manufacturing
Organisational Requirements for Additive Manufacturing
Training and Qualifications
6 Design
Software Translation
10
Control of Powder Feedstock
10
9 Build
11
10
Post Processing
12
11
Inspection and Testing
13
12
Intellectual Property
14
13
References
14
Health and Safety
15
Appendix
Lloyds Register Group Limited and TWI Ltd 2016. All rights reserved.
Published by Lloyds Register Group Limited. Registered office (Reg. no. 08126909), 71 Fenchurch Street, London, EC3M 4BS, United Kingdom.
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Section
1 Introduction
2
Suitability for Additive Manufacturing
Organisational Requirements for Additive
Manufacturing
5
6 Design
7
9 Build
10 Post Processing
11 Inspection and Testing
Section 1
1.3 Scope
The scope of this document is the additive manufacturing of
metallic parts using Laser Metal Deposition (LMD) techniques
(see Figure 1); or Laser Powder Bed Fusion (PBF) processes (see
Figure 2); and the application of metal layers on parts during
manufacture using LMD techniques.
The use of AM for repair is not within the scope of this document.
For guidance on part repair using specific AM techniques (i.e.
flame, arc, plasma and High Velocity Oxygen Fuel (HVOF)
spraying), refer to Lloyds Register Materials and Qualification
Procedures for Ships Book L, Procedure 15-1.
Other AM processes and materials (e.g. non-metallic) may
be consideredon a case-by-case basis, following special
consideration by the Inspection Authority.
12 Intellectual Property
13 References
Section 1
Introduction
1.4 Hierarchy and Terminology

Figure 3 illustrates the hierarchy of the AM scope and the
primary currently preferred terms (defined within ISO/ASTM
52900:2015).
Figure 1 Laser Metal Deposition
1.1 Purpose
The purpose of this document is to provide industry with
goal-based certification guidelines for the manufacture of
metallic parts/components using additive manufacturing (AM).
1.2 General
The basis of the design, manufacture and inspection of any
part intended to be manufactured by AM will require a study
of the functional requirements of that part. This is because the
inspection requirements will be specific to that part and the AM
process used.
The outcome of this functional study, together with the existing
requirements of the applicable codes and regulations, will define
the aspects to be demonstrated in order for the part to be
certified.
In the future, as and when prescriptive requirements are
developed and established by industry, such considerations
will become the norm and embedded in code or regulatory
acceptance criteria. Until then, these goal-based guidelines
provide a basis for achieving a design, manufacture and
inspection methodology for AM, which achieves equivalence
with conventional subtractive manufacturing techniques.
Figure 2 Laser Powder Bed Fusion
Section 1
Figure 3 Standard Terminology for AM
Other AM processes (defined within ISO/ASTM 52900:2015) are

not covered by this document.
Section 2

2.1 Abbreviations
Section 2
2.2 Definitions
3D CAD modelling
(solid modelling)
The process most commonly used during

design to produce a digital 3D model.
3D scanning (3D
digitising)
Method of acquiring the shape and

size of an object as a 3D representation
by recording x, y, z coordinates on the
objects surface and using software to
convert into digital data.
Additive
Manufacturing
(AM)
A process by which digital 3D design data

is used to build up a parts in layers by
depositing material.
Additive
Manufacturing
Format (AMF)
File format for communicating AM model

data including a description of the 3D
surface geometry with native support
for colour, materials, lattices, textures,
constellations and metadata.
Build chamber
Enclosed volume within the AM system

where the parts are fabricated.
Directed Energy
Deposition (DED)
Additive manufacturing process in which

focused energy is used to fuse materials
by melting as they are being deposited.
3D
Three Dimensional
AM
AMF
Additive Manufacturing Format
Ar
Argon
ASME
American Society of Mechanical Engineers
CAD
Computer Aided Design
DED
Directed Energy Deposition
EAI
External Authoring Interface
He
Helium
HVOF
High Velocity Oxygen Fuel
IP
ISO
International Standards Organisation
LMD
Laser Metal Deposition
MSDS
Material Safety Data Sheet
NDE
Non-Destructive Examination
NIST
National Institute of Standards and

Technology
Feedstock
Bulk raw material supplied to the AM

building process.
O2
Oxygen
File format
OEM
Original Equipment Manufacturer
PBF
Powder Bed Fusion
PPE
Personal Protective Equipment
VRML
Virtual Reality Modelling Language

(ISO/IEC 14772-1:1997 and ISO/IEC
14772-2:2004)
File format for model data (e.g. STL or

AMF) describing the surface geometry
of an object as a tessellation of triangles
used to communicate 3D geometries to
machines in order to build physical parts.
Fusion
The act of melting and combining

materials through the application of
energy.
Laser melting
Powder Bed Fusion process used to

produce objects from powdered materials
using one or more lasers to selectively
fuse or melt the particles at the surface,
layer upon layer, in an enclosed chamber.
Laser Metal
Deposition (LMD)
Directed Energy Deposition process in

which lasers are used to fuse powdered
materials by melting as they are being
deposited.
Laser sintering
Powder Bed Fusion process used to

produce objects from powdered materials
using one or more lasers to selectively
sinter the particles at the surface, layer
upon layer, in an enclosed chamber.
Part
Fused material forming a functional

element that could constitute all or a
component of an intended product.
Porosity
Small voids in the internal structure of a

part, making it less than fully dense.
Post processing
Process steps taken after an AM

build in order to achieve the desired
characteristics in the final product.
Powder Bed Fusion Additive manufacturing process in which

(PBF)
focused energy selectively fuses regions of
a powder bed.
Process parameters Set of operating parameters and system
settings used during a build operation.
Repeatability
Degree of alignment of two or more

measurements of the same property using
the same equipment and in the same
environment.
STL
File format for model data to represent

component geometry as a tessellation of
triangles.
Subtractive
Manufacturing
Any of the various processes in which

material is removed to produce a part of a
desired shape and size.
Surface
Tessellation
Language (STL)
File format for model data describing

the surface geometry of an object
as a tessellation of triangles used to
communicate 3D geometries to machines
in order to build physical parts.
Used powder
Powder that has been reprocessed after

at least one previous build cycle.
Virgin powder
Unused powder from a single powder lot.
Sections 2 & 3
Section 3
Suitability for
It should be noted that AM is often one of many processes
that a designer or purchaser may choose for production.
When determining whether the use of AM is appropriate,
the manufacturer should consider in the context of other
manufacturing routes with the potential
to meet their
requirements. The following list provides some of the
considerations which can support the selection of a manufacturing
process. It is not exhaustive and is included here for guidance
only.
Complexity
Does the complexity of parts result in high

costs?
There is a direct relationship between part
complexity and cost using conventional
subtractive manufacturing techniques due
to the number of individual operations.
For complex designs, AM might be
considered more cost-effective as build
time is not affected by complexity (part
size and finishing processes largely dictate
cost for AM). AM currently has higher
comparable part costs for simple parts.
Current situation
Am I happy with current part supply?

AM is an alternative manufacturing
technology but the current supply chain
may be sufficient for your needs.
Lead time
Are lead times acceptable for parts

made by conventional manufacturing
methods (e.g. casting, forging, complex
machining)?
Where lead times are unacceptable, AM
might be considered as an alternative.
Material cost
Are my parts made from expensive

metals?
For parts that are machined from large
blocks of expensive material the level of
material wastage can be significant. The
layered construction of AM can reduce
material wastage.
Metallurgical
structure
What is the metallurgical structure of the

part?
Consideration should be given to the
importance of metallurgical structure in
achieving the properties and function
of the part. AM is more suited to parts
having a single phase cast structure.
Multiple
operations
Does the part require multiple operations

during manufacture?
Multiple conventional manufacturing
operations (e.g. casting, milling, turning,
drilling, welding) can often be replaced
by just one AM build, thus simplifying
the overall process. Post processing
requirements, such as surface finishing,
should be taken into account before
selecting AM.
Part optimisation
Section 3
Shipping time
and cost
Can I wait for completed parts to be

shipped from the place of manufacture?
The ability to distribute AM files
and parameters digitally to a local
manufacturing centre can lead to
reduced shipping times and costs. It
should be noted that these guidelines
would have to be applied to all
anticipated manufacturing centres (as
build parameters do not transfer directly
between different AM machines and
facilities).
Do I want to have unique optimised parts

that cannot be made by conventional
methods?
AM offers the designer greater
freedom to optimise the design for
critical requirements (e.g. strength,
performance), with fewer constraints on
manufacturability.
Production size
How many identical parts will I require?

Currently, AM is most suited to smaller
production runs. Costs for large volumes
are expected to be higher when using
AM, especially where parts are not
complex and can be simply produced by
conventional subtractive manufacturing
techniques.
Reverse
engineering
Do I need parts that are no longer

available in the market-place?
When design data is not available (e.g. for
obsolete parts), AM coupled with a 3D
scanning technology, offers the ability to
recreate, modify and adapt existing parts.
Section 4
Organisational Requirements for

The complete AM process from concept through build and inservice inspection is controlled by an organisation of interested
parties. Typically this could be the designer, the programmer, the
AM manufacturer, the purchaser, the end user, an Inspection
Authority (if requested) or any combination of these.
The organisation shall determine:
The identity of the interested parties relevant to the part
intended to be manufactured by AM.
The requirements of these interested parties.
The requirements of interested parties may include, national
and international standards, international or national regulatory
requirements, industry codes of practice and contractual
requirements.
4.1 Design and Development Planning

In determining the stages and controls for design and
development, the organisation shall consider:
The nature, duration and complexity of the design and
development activities.
The required process stages, including applicable design and
development reviews.
The required design and development verification and
validation activities.
The responsibilities and authorities involved in the design
and development process (e.g. involvement of an Inspection
Authority, if requested by the end user or by a code or
standard).
The internal and external resource needs for the design and
development of products and services.
The need to control interfaces between persons involved in
the design and development process.
The need for involvement of customers and users in the design
and development process.
The requirements for subsequent provision of parts intended
to be manufactured by AM.
The level of control expected for the design and development
process by customers and other relevant interested parties.
The documented information needed to demonstrate that
design and development requirements have been met.
4.2 Design and Development Inputs

The manufacturer shall determine the requirements that are
essential for the AM part.
Section 4
The organisation shall consider:

Functional and performance requirements.
Any critical customer quality requirements.
Information derived from previous similar design and
development activities.
Statutory and regulatory requirements.
Standards or codes of practice that the organisation has
committed to implement.
Potential consequences of failure due to the nature of the
products and services.
Inputs shall be adequate for design and development purposes,
complete and unambiguous. Conflicting design and development
inputs shall be resolved.
The organisation shall retain documented information on design
and development inputs.
4.3 Design and Development Controls

The organisation shall apply controls to the design and
development process to ensure that:
The results to be achieved are defined.
Reviews are conducted to evaluate the ability of the results of
design and development to meet requirements.
Verification activities are conducted to ensure that the design
and development outputs meet the input requirements
(consideration should be given at the design stage as to how
the final part will be inspected and which NDE techniques
would be most appropriate, or requested by a specific code
or standard).
Validation activities are conducted to ensure that the
resulting parts intended to be manufactured by AM meet the
requirements for the specified application or intended use.
Any necessary actions are taken on potential issues determined
during the reviews, or verification and validation activities.
Documented information of these controlling activities is
retained.
Design and development reviews, verification and validation
have distinct purposes. They can be conducted separately or in
any combination, as appropriate to the products and services of
the organisation.
4.4 Design and Development Outputs

The organisation shall ensure that design and development
outputs:
Meet the input requirements.
Are adequate for the subsequent processes for the provision
of parts intended to be manufactured by AM.
Include or reference monitoring and measuring requirements,
as appropriate, and acceptance criteria.
Specify the characteristics and appropriate acceptance criteria
of the parts intended to be manufactured by AM that are
essential for their intended purpose and their safe and proper
provision.
The organisation shall retain documented information on design
and development outputs.
4.5 Design and Development Changes
Section 4
The implementation of a risk-based maintenance plan.
4.7 Actions to Address Risks

When planning for the design, manufacture and inspection of
parts intended to be manufactured by AM, the organisation shall
consider the needs and expectations of the interested parties and
the requirements related to quality, environment and health and
safety.
The organisation shall identify, review and control changes made

during, or subsequent to, the design and development of parts
intended to be manufactured by AM, to the extent necessary
to ensure that there is no adverse impact on conformity to
requirements.
The manufacturer shall submit a risk analysis that addresses the

following:
Assurance that the parts intended to be manufactured by AM
achieve their intended outcomes.
Prevention or reduction of undesired effects.
The organisation shall retain documented information on:

Design and development changes (e.g. changes to personnel
and/or software used).
The results of reviews.
The authorization of the changes.
The actions taken to prevent adverse impacts.
The organisation shall plan actions to reduce or remove these

risks, and define how to:
Integrate and implement the actions into its design,
manufacturing and inspection processes.
Evaluate the effectiveness of these actions.
4.6 Control of Production

The organisation shall implement production of AM parts under
controlled conditions.
Controlled conditions shall include, as applicable:
The availability of documented information that defines:
The characteristics of the products to be produced.
The results to be achieved.
The AM machine model and firmware revision used.
The availability and use of suitable monitoring and measuring
resources.
The implementation of monitoring and measurement
activities at appropriate stages to verify that criteria for control
of processes or outputs, and acceptance criteria for products
have been met.
The use of suitable infrastructure and environment for the
operation of processes (i.e. control of any system, process
or software that is required to manufacture the part to the
necessary level of quality and meet the client requirements).
The appointment of competent persons, including any
required qualification.
The validation, and periodic revalidation, of the ability to
achieve planned results of the processes for production,
when the resulting output cannot be verified by subsequent
monitoring or measurement.
The implementation of processes and procedures to prevent
human error.
The implementation of release, delivery and post-delivery
activities.
4.8 Leadership and Commitment

The top management of the organisation shall demonstrate
leadership and commitment with respect to the design,
manufacture and inspection of the parts intended to be
manufactured by AM by:
Ensuring that the resources needed for the parts intended to
be manufactured by AM are available.
Ensuring that parts intended to be manufactured by AM
achieve their intended outcomes.
Supporting other relevant management roles to demonstrate
their leadership as it applies to their areas of responsibility.
Ensuring that any subcontracted operations are subject to
adequate controls and inspection criteria in accordance with
relevant quality requirements and these guidelines.
4.9 Resources
The organisation shall determine and provide the resources
needed for the design, manufacturing and inspection and
continual improvement of the parts intended to be manufactured
by AM.
4.10 Competence
The organisation shall:
Demonstrate the competence of the primary personnel roles
of:
Designer.
Programmer.
Machine operator.
Inspector.
Ensure that these personnel are competent on the basis of
appropriate education, training, or experience.
Whenever necessary, take actions to acquire the necessary
competence, and evaluate the effectiveness of the actions
taken.
Retain appropriate documented information as evidence of
competence.
Sections 4 & 5
Section 5
The quality of parts manufactured by AM techniques is very

dependent on the training and skill of personnel.
Records shall demonstrate qualifications and necessary
competence in the AM process of personnel by presenting a
training record, which includes but is not limited to the following:
Training certificates.
On-the-job training records.
Documented experience.
Evidence of health and safety awareness commensurate
with the risk. Refer to Appendix 1 - Health and Safety for
information.
Section 6
Design
6.1 General
For parts manufactured by AM, the designer shall establish,

implement and maintain a design and development process that
is appropriate to ensure the subsequent provision of parts that
meet customer and regulatory requirements.
Section 6
Similarly, Lloyds Register Rules allow divergence from prescribed

requirements and where this is proposed, the alternative
requirements will be derived on a case by case basis.
The designer shall consider introducing a suitable design factor
(such as that used for cast parts in ASME BPVC-VIII-1) and the
mechanical properties assumed in design must be proved during
testing. Provided the part is manufactured as modelled and
meets the requirements specified within the design code, when
applicable, then the design may be accepted on that basis.
6.2 Criticality versus Probability

A study should be undertaken as part of the design activity to
determine the possible consequences and probability of part
failure. Using the matrix in Figure 4, the level of risk shall be
determined from the product of consequence and probability.
Where necessary, the risks shall be mitigated to an acceptable
level and the rigorousness of the Third Party Inspection required
will be based upon this risk level (to be agreed on a case-by-case
basis). The risk assessment can also be used to assess whether the
most suitable AM process has been selected.
Figure 4 Probability versus Consequence Matrix
6.3 Standards and Regulations

If a standard is used as the basis for design that does not include
parts made by AM then it must include a clause allowing the
manufacturer to demonstrate an equivalent level of safety with
alternative materials and alternative methods of design and
manufacture. For example, ASME BPVCVIII-1 does not cover AM
but clause U-2(g) allows deviation from the rules provided that the
manufacturer can demonstrate details of design and construction
which are as safe as those provided by the rules of that standard.
Sections 7 & 8
Section 7
Section 8
The translation of the 3D Computer Aided Design (CAD) model

into build machinery software requires careful consideration of
various factors including:
Respective coordinate systems at all data import and export
stages.
3D model export translation accuracy, especially with respect
to critical features.
The impact of software updates on the translation of legacy
parts.
Determination of scanning strategy and speed.
8.1 General
For further information, refer to ISO 17296-4 Additive

Manufacturing General Principles Part 4 Overview of Data
Processing.
Powder feedstocks are hazardous. Refer to Appendix 1 - Health

and Safety for information.
The chemical composition, physical size and distribution of
particles in powder feedstocks are process parameters; it is
therefore very important to control the selection, storage and
testing of powder feedstocks down to a single batch level.
Powder feedstock must always be disposed of safely in compliance
with national/international laws and regulations.
8.2 Selection
A list of the information required on a powder material certificate,
is as follows:
Powder supplier contact information.
Packing date.
Unique identification of the powder (batch number).
Chemical composition (including crystalline phases and test
methods).
Thermal characteristics (melting temperature).
Particle size and distribution evaluation method and results,
for example, sieving or laser diffraction (ISO 13320 Particle
Size Analysis Laser Diffraction Method).
Packaging and storage instructions recommended by the
supplier (specifying maximum oxygen content).
Powder content outside the range specified.
Powder flow properties (ISO 4490 Metallic Powders
Determination of Flow Rate by Means of a Calibrated Funnel
(Hall Flowmeter)).
Material Safety Data Sheet (MSDS).
If any of the required information is not available on the powder
material certificates then further testing shall be conducted to
determine the missing information.
For further information, refer to ISO 17296-2 Additive
Manufacturing General Principles Part 2 Overview of Process
Categories and Feedstock.
8.3 Storage
Powder feedstock storage, must:
Keep feedstocks in separate, labelled, sealed containers in a
designated dry storage area.
Prevent contamination between different feedstocks and
different batches of the same feedstock, especially when
transferring powders from one canister to another vessel.
Prevent the inadvertent mixing of virgin and used feedstock.
10
8.4 Testing
Due to the inert environment within a Laser PBF machine the
powder feedstock may be sieved and reused.
The number of times laser powder bed feedstock is reused shall
be tracked and the oxygen content of used powder measured
and compared against allowable levels (as provided on the
material certificate). The checking procedure shall be sufficiently
frequent to eliminate the risk of unsuitable feedstock being used
during manufacturing.
Reused powder feedstock shall never be used in the LMD process
but may be used for set-up procedures only.
Sections 8 & 9
Section 9
Build
9.1 Overview of Additive Manufacturing

Methods
9.1.1 Build Machinery
Adequate procedures, for example standard operating procedures
and part specific work instructions and risk assessments shall be
provided to ensure the quality of the final part.
Detailed relevant site specific installation, operating, maintenance
and test procedures shall be provided in line with the requirements
of the AM machine Original Equipment Manufacturer (OEM).
The procedures shall include all necessary information including
the frequency of:
Preventative maintenance.
Performance tests.
Calibration.
It is recognised that build parameters do not transfer directly
between different AM machines and further testing would be
required if plans were made to produce previously certified
parts on a different AM machine. The following list provides an
example of some characteristics that vary between machines,
leading to different results:
Laser beam profile.
Laser absorption/reflectivity (e.g. the substrate material may
require shot-blasting to reduce reflectivity).
Laser behaviour (e.g. possible loss of energy).
9.1.2 Auxiliary Systems

The purity of the gas used in gas shielding is an important process
parameter. It can be determined from the gas quality certificate.
Selection and maintenance of the gas delivery system
(including pipework) shall consider gas purity and avoidance of
contamination.
9.1.3 Laser Metal Deposition Process

Parameters and Effects
Understanding, control and traceability of the following
parameters shall be demonstrated:
Laser (power at workpiece and spot dimensions).
Powder feedstock (particle size range and distribution,
morphology, impurity type, concentration, feed rate, flow
rate, deposition rate).
Chemical composition of powder feedstock.
Nozzle (co-axial, 3-beam or side-feeder).
Traverse speed.
Shielding gas (Ar or He, gas flow).
11
Stand-off distance (i.e. distance between nozzle tip and
surface).
Heat input and cooling characteristics.
Control of external parameters (e.g. temperature, humidity).
Possible effects that may occur due to the choice of process
parameters, and which may be reduced or eliminated by the
optimisation of process parameters, include:
Distortion.
Contamination (with different powder or O2 contamination).
Lack of repeatability/consistency.
Inconsistent results when transferring process conditions to
different geometries.
Excessive/insufficient dilution with substrate.
Porosity (e.g. due to certain powder morphology and alloy
selection).
Cracking (various types and conditions of cracking; pre-heat
required for crack-sensitive materials).
Surface finish quality.
Sections 9 & 10
Section 10
Post Processing
10.1 General
Consideration shall be given to the removal of supports and any
necessary machining operations to ensure that they do not have
a detrimental effect on the integrity of the part.
Residual stresses shall be considered and measures such as
heat treatment (according to material, code and application
requirements) should be undertaken to ensure that stresses are
reduced to an acceptable level.
Documentary evidence of the procedures performed and
equipment used (for example furnace chart) shall be retained.
Before inspection the part shall be removed from the build
machinery with any excess powder removed, and the part shall
be cleaned.
9.1.4 Laser Powder Bed Fusion Process

Parameters and Effects
Understanding, control and traceability of the following
parameters shall be demonstrated:
Laser (power, spot dimensions, exposure time, focus position).
Scanning strategy.
Powder feedstock (particle size range and distribution,
morphology, impurity type, concentration).
Chemical composition of powder feedstock.
Inert environment (e.g. argon gas).
Point distance (distance between successive laser spots).
Hatch distance and conditions (shift between tracks in the
plane of the beam scanning; track distance).
Boundary conditions.
External parameters (e.g. temperature, humidity).
Possible effects that may occur due to choice of process
parameters, and which may be reduced or eliminated by
optimisation of process parameters:
Porosity.
Lack of fusion.
Balling (defect where small spheres form leading to
discontinuities in the fusion path).
Cracking.
De-lamination.
High residual stresses (influence the dimensional accuracy of a
part and the risk of cracking).
Difficulty achieving repeatability and accuracy.
Contamination (typically caused by change of powder and/or
oxygen contamination).
Surface finish (may require machining - considered as near net
shape).
12
Section 11
Inspection and Testing
11.1 General
Because repeatability, accuracy and consistency are important
aspects when producing AM parts (either LMD or Laser PBF),
the selected testing and inspection regime must be sufficiently
rigorous to take into account the criticality of the part and the
potential impact of any lack of repeatability of the AM technique.
The selected design code will drive the quality level required,
which will establish the critical defect (indication) size, and
therefore, which non-destructive examination (NDE) methods are
appropriate. If considered necessary, destructive testing might
also be applied. The final selection of NDE methods shall consider
the complexity of the part, the criticality of the application, and
any inspection limitations.
The inspection shall include at least all of the following procedures,
unless specially agreed by the Inspection Authority:
100% visual examination.
100% dimensional examination.
If the part is subject to dynamic loading, the fatigue performance
shall be specified within the acceptance criteria.
The quality assurance department shall retain manufacturing
records (job control records), along with testing and inspection
reports.
Parts manufactured by AM may be susceptible to post
manufacture distortion and cracking. Therefore, all dimensional
checks and NDE shall only be undertaken once the part is no
longer subject to post manufacturing effects (e.g. after a suitable
cooling period, which is dependent upon part and material).
Section 11
11.3 Mechanical Testing

Mechanical testing shall be undertaken on test specimens and
the final product, as required. Mechanical testing requirements
will be specific to the part geometry and application and are
therefore to be agreed with the Inspection Authority.
Test specimens shall be representative of the part, taking into
account mechanical properties and geometry. Consideration shall
also be given to minimum and maximum feature size within the
part and the build orientation.
For further information, refer to Sections 4 and 5 of
ISO 17296-3 Additive Manufacturing General Principles Part 3:
Main Characteristics and Corresponding Test Methods.
Also refer to the appropriate design code for the test requirements
specific to the application. For further information, refer to NISTIR
8005 Applicability of Existing Materials Testing Standards for
Additive Manufacturing Materials.
11.4 In-Service Inspection

The frequency of in-service inspection will align with standard
procedures but may be enhanced based upon:
Criticality (refer Section 6.2).
Any test or inspection limitations identified in the part during
previous NDE examinations.
The geometry and stress distribution.
The maturity of the AM technique at the point in time of
manufacture.
Whether continuous condition monitoring is carried out.
For further information, refer to Sections 4 and 5 of

ISO 17296-3 Additive Manufacturing General Principles Part 3:
Main Characteristics and Corresponding Test Methods.
11.2 Surface Finish

It is often necessary to modify the surface finish of AM parts,
especially if a specific roughness is required (e.g. to be compatible
with a gasket).
The designer shall specify the surface finish requirements of the
part and select suitable post processing operations to achieve the
required finish.
13
Section 12
Designs used for AM are subject to current laws governing

intellectual property (IP) and copyright. The IP of the design,
along with the 3D CAD model and the manufacturing
STL/AMF files, must be strictly controlled.
Designs, 3D CAD models and manufacturing files are protected
by copyright. Any organisation utilising designs, 3D CAD models
or manufacturing files shall retain evidence of the appropriate
copyright licences.
14
Sections 12 & 13
Section 13
References
ASME
BPVC-VIII-1
ASME Section VIII Division 1 Rules for

Construction of Pressure Vessels.
HSG103
Safe Handling of Combustible Dusts:

Precautions against Explosions.
IEC 60079-10-2
Explosive Atmospheres Part 10-2:

Classification of Areas Explosive Dust
Atmospheres.
ISO 13320
Particle Size Analysis Laser Diffraction

Method.
ISO 4490
Metallic Powders Determination of Flow

Rate by Means of a Calibrated Funnel
(Hall Flowmeter).
ISO 9001
Quality Management Systems
ISO 17296-2
Additive Manufacturing General Principles

Part 2 Overview of Process Categories and
Feedstock.
ISO 17296-3
Additive Manufacturing General

Principles Part 3 Main Characteristic and
Corresponding Test Methods.
ISO 17296-4

Part 4 Overview of Data Processing.
ISO/ASTM
52900:2015

Terminology.
ISO/IEC
14772-1:1997
Information Technology Computer

Graphics and Image Processing The
Virtual Reality Modelling Language Part
1: Functional Specification and Utf-8
Encoding.
ISO/IEC
14772-2:2004
Information Technology Computer

Graphics and Image Processing The Virtual
Reality Modelling Language (VRML) Part
2: External Authoring Interface (EAI).
Lloyds Register
Materials and
Qualification
Procedures for
Ships
Lloyds Register Materials and Qualification

Procedures for Ships Book L, Procedure
15-1, Approval Scheme for Firms
Undertaking Thermal Spraying Processes.
NISTIR 8005
Applicability of Existing Materials Testing

Standards for Additive Manufacturing
Materials.
Appendix 1
Health and Safety
This section lists the typical health and safety hazards associated
with AM along with the duties of the AM workplace and
individuals attending the workplace.
Appendix 1
A1.3.1 Argon (Ar)

Ensure that the working environment meets national/international
laws and regulations.
Main Hazards
Asphyxiant.
Effect of
Inhalation
A1.1 General
The following is a list of the typical hazards and hazardous
materials associated with AM:
Dust fire and explosion hazards.
Shielding gases, typically argon and helium.
Lasers.
Moving machinery.
Powder feedstock (e.g. 316L stainless steel).
First Aid
Measures
The fine metal powder feedstocks used for AM presents a dust

fire and explosion hazard.
Adequate extraction facilities shall be provided to ensure working

environment meets national regulatory requirements (IEC 6007910-2 or equivalent).
A1.3 Shielding Gases

Typically, Ar and He are used as the shielding gases. If other
shielding gases are required then this shall be agreed with the
Inspection Authority.
Hazardous gases shall be stored in vented gas cabinets. Adequate
extraction facilities shall be provided. Gas alarms are required for
any confined space that has gas storage or systems. Gas alarms
must be capable of detecting the presence of gas or significant
decreases in gas pressure. Any emergency exits within the
confined space must open outwards.
Remove victim to uncontaminated

area wearing self contained breathing
apparatus. Keep victim warm and rested.
Call a doctor. Apply artificial respiration if
breathing has stopped.
If breathing has stopped or is laboured,
give assisted respirations. Supplemental
oxygen may be indicated. If the heart
has stopped, trained personnel should
begin cardiopulmonary resuscitation
immediately. In case of shortness of
breath, give oxygen.

For further information, refer to HSG103 Safe Handling of

Combustible Dusts: Precautions against Explosions or equivalent.
In high concentrations may cause

asphyxiation. Asphyxiation may bring
about unconsciousness without warning
and so rapidly that victim may be unable
to protect themselves.
Exposure to oxygen deficient atmosphere
may cause the following symptoms:
dizziness, salivation, nausea, vomiting,
loss of mobility and consciousness.
A1.2 Dust, Fire and Explosion Hazards
Dust explosion alarms shall be considered and installed if

necessary.
High Pressure Gas.
For comprehensive information, including, accidental release

measures; and handling and storage information, refer to the
Material Safety Data Sheet (MSDS). Wear appropriate Personal
Protective Equipment (PPE) as specified on the MSDS.
A1.3.2 Helium (He)

Main Hazards
High Pressure Gas.

Asphyxiant.
Effect of
Inhalation
In high concentrations it may cause

asphyxiation. Symptoms may include loss
of mobility/consciousness. Victim may not
be aware of asphyxiation.
First Aid
Measures

breathing has stopped.
For comprehensive information, including, accidental release

measures; and handling and storage information, refer to the
MSDS. Wear appropriate PPE as specified on the MSDS.
15
A1.4 Lasers
Lasers are the source of energy to melt powder during LMD and
Laser PBF processing.
Main Hazards
Effect of
Exposure
Severe injury or death.
Precautions
Only trained, authorized personnel

may operate lasers. Consult the build
machinery OEM safety instructions and
wear appropriate PPE.
A1.5 Powder Feedstock

Irritants and toxins which, due to
their small particle size, can affect the
respiratory system and can enter the body
through exposed skin.
Highly flammable and can be explosive
(the build and storage areas may need to
be fitted with combustible dust detection
systems).
Slip hazard on smooth floors.
Effect of
Inhalation
Danger of serious damage to health by

prolonged exposure through inhalation.
Effect of Skin
Contact
May cause sensitisation by skin contact.
First Aid
Measures

breathing stopped.
Precautions
For comprehensive information, about specific powder

feedstocks, including, accidental release measures; and handling
and storage information, refer to the MSDS. Wear appropriate
PPE as specified on the MSDS.
Laser radiation.
Intense Heat and Light Hazards.
Main Hazards
Appendix 1
Ensure adequate ventilation of the

working area. Keep personnel away from
spills. Avoid formation of dust.
Wear the following PPE:
Overalls.
Safety boots.
Disposable nitrile rubber gloves.
Protective glasses.
When particle sizes are less than 20
microns, wear self-contained breathing
apparatus
A1.6 Robots
Main Hazards
Robot collision.
Entrapment.
Effect of Collision Severe injury or death.

Precautions
Only trained, authorized personnel may

operate robots or other manipulation
equipment. Consult the build machinery
OEM safety instructions and wear
appropriate PPE.
Programmes should be run from outside
the deposition cell (working area of
the robot and laser system). Interlock
systems are commonly used between
the deposition cell and control area to
prevent unplanned usage of the robot
manipulation and the laser system. Speed
limiters are one method of reducing the
risk of a high speed collision and can
be set to trigger when the interlock is
broken.
When required, programming or
moving the robot position from inside
the deposition cell, a teach pendant is
recommended with a dead mans safety
control system.
The working envelope of the robot and
machinery should be marked on the floor,
creating safe to stand areas.
A1.7 Duties of Manufacturers and

Individuals
Comply with national/international laws and regulations; site
health and safety rules information and guidance, including
those provided on:
Operating and inspection procedures.
MSDS.
When hazardous fumes are present

and/or particle sizes are greater than 20
microns, wear a mask respirator. The
mask filter must be the appropriate type
for the particle size.
16
Lloyds Register
71 Fenchurch Street
London EC3M 4BS, UK
T +44 (0)20 7709 9166
F +44 (0)20 7488 4796
www.lr.org
TWI Ltd
www.twi-global.com
Working together
for a safer world

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Guidance Notes

Guidance Notes for Additive Manufacturing of Metallic Parts, January 2016

Guidance Notes for

Lloyds Register and TWI

Guidance Notes for Additive Manufacturing of Metallic Parts, January 2016

Additive Manufacturing of Metallic Parts

Abbreviations and Definitions

Suitability for Additive Manufacturing

Organisational Requirements for Additive Manufacturing

Training and Qualifications

Control of Powder Feedstock

Inspection and Testing

Health and Safety

Guidance Notes for Additive Manufacturing of Metallic Parts, January 2016

Abbreviations and Definitions

Suitability for Additive Manufacturing

Organisational Requirements for Additive

Training and Qualifications

Control of Powder Feedstock

1.4 Hierarchy and Terminology

Lloyds Register and TWI

Guidance Notes for Additive Manufacturing of Metallic Parts, January 2016

Figure 3 Standard Terminology for AM

Other AM processes (defined within ISO/ASTM 52900:2015) are

Lloyds Register and TWI

Guidance Notes for Additive Manufacturing of Metallic Parts, January 2016

Abbreviations and Definitions

The process most commonly used during

Method of acquiring the shape and

A process by which digital 3D design data

File format for communicating AM model

Enclosed volume within the AM system

Additive manufacturing process in which

Additive Manufacturing Format

American Society of Mechanical Engineers

Computer Aided Design

Directed Energy Deposition

External Authoring Interface

High Velocity Oxygen Fuel

International Standards Organisation

Laser Metal Deposition

Material Safety Data Sheet

National Institute of Standards and

Bulk raw material supplied to the AM

Original Equipment Manufacturer

Powder Bed Fusion

Personal Protective Equipment

Virtual Reality Modelling Language

File format for model data (e.g. STL or

The act of melting and combining

Powder Bed Fusion process used to

Directed Energy Deposition process in

Powder Bed Fusion process used to

Fused material forming a functional

Small voids in the internal structure of a

Lloyds Register and TWI

Guidance Notes for Additive Manufacturing of Metallic Parts, January 2016

Process steps taken after an AM

Powder Bed Fusion Additive manufacturing process in which

Degree of alignment of two or more

File format for model data to represent

Any of the various processes in which

File format for model data describing