The qualification of additive manufacturing (AM) processes and the certification of AM parts is recognized as a significant impediment to the rapid, low-cost deployment of AM manufacturing. The challenges are multifaceted; however, it is an attempt to apply conventional qualification approaches to an inherently different process that has caused the most difficulty. This article examines the conventional qualification methodology and explores how the unique characteristics of AM pose a set of qualification challenges. The extant approach to the qualification of AM processes is described, followed by a discussion on a possible future state.

Independent verification of coating system performance can be based on laboratory testing and/or field exposure. Qualification testing is a critical component to coating system selection. This article focuses on performance evaluations that are used to prequalify coating systems, namely, facility-specific, industry-specific, coating-type-specific, or a combination of these. It describes the standard laboratory tests used to generate performance data, namely, physical, compositional, chemical exposure, and application characteristics tests. The pros and cons of using manufacturer-generated data versus independently generated data are discussed. The article provides information on accelerated corrosion/weathering testing and nuclear level 1/level 2 service coatings qualification. It also describes the procedures for establishing minimum performance requirements and for determining when requalification testing may be required.

Qualification of welding procedures and personnel is an important step to assure the quality and performance of any welded component or structure. This article summarizes common welding procedures, personnel qualification variables, and test methods. Welding procedure qualification tests can be categorized as either standard or special. The article discusses the purpose of qualifying a welding procedure to demonstrate that the resulting welds will meet prescribed quality standards and the qualification of the personnel.

Welding codes and standards usually require the qualification of welding procedures prior to being used in production. This is to ensure that welds will meet the minimum quality and mechanical property requirements for the application. This article provides an overview of the welding procedure qualification guidelines and test methods. It also reviews the codes, standards, and specifications that govern the design and fabrication of welded structures for the procedure qualification details that are appropriate for a given application.

This article presents the use of additive manufacturing (AM) in the space industry. It discusses metal AM processes and summarizes metal AM materials, including their relevant process categories and references. It also presents the design for AM for spacecraft. The article also provides an overview of in-space manufacturing and on-orbit servicing, assembly, and manufacturing. It presents some of the specific areas that must be understood for the qualification of AM. The article also discusses future trends, challenges, and opportunities for aerospace.

This article presents the history of standardization in additive manufacturing (AM). It explains the need and structure for standardization in AM, including the application of AM standards by the industry sector. It also presents the primary purposes of these standards to create AM qualification and certification frameworks.

This article discusses some of the additive manufacturing (AM) based fabrication of alloys and their respective mechanical, electrochemical, and in vivo performance. Firstly, it briefly discusses the three AM techniques that are most commonly used in the fabrication of metallic biomedical-based devices: binder jetting, powder-bed fusion, and directed-energy deposition. The article then characterizes the electrochemical properties of additive-manufactured/processed cobalt-chromium alloys. This is followed by sections providing an evaluation of the biological response to CoCr alloys in terms of the material and 3D printing fabrication. Discussion on the biological response as a function of direct cellular activity on the surface of CoCr alloys in static conditions (in vitro), in dynamic physiological conditions (in vivo), and in computer-simulated conditions (in silico) are further discussed in detail. Finally, the article provides information on the qualification and certification of AM-processed medical devices.

This article discusses the standard test methods that can be applied to many types of welds: tension, bending, impact, and toughness testing. It provides information on four qualification stages, namely, the weld material qualification, base material qualification, the weld procedure qualification, and the weld service assessment. The article describes two general types of measurements for residual stress in welds: locally destructive techniques and nondestructive techniques. Locally destructive techniques include hole drilling, chip machining, and block sectioning. Nondestructive techniques include X-ray diffraction, neutron diffraction, Barkhausen noise analysis, and ultrasonic propagation analysis. The article concludes with an overview of weldability testing.

This article discusses the development of a welding procedure for friction stir welding (FSW), including the process of defining a preliminary procedure, the optimization of parameters, the development of supporting data, and other key features to ensure a successful procedure. The critical features of FSW tool design, initial process parameters, systematic welding trials, and robustness testing are reviewed. The article provides information on the common features of welding procedure qualification. It also includes a table that lists the procedures used in the production of sound friction stir welds in various aluminum alloys.