Laser Thermography as Non-Destructive Technique to Detect Defects in AlSi10Mg Parts Printed with L-PBF Process

In additive manufacturing (AM), particularly with AlSi10Mg aluminum alloy produced via Laser Powder Bed Fusion (L-PBF), understanding and detecting defects is crucial for ensuring mechanical integrity. This study evaluates the effectiveness of active thermography as a fast, non-destructive testing (NDT) method for identifying typical L-PBF defects. Artificial defects (cubes, spheres, cylinders with unfused powder) were introduced by varying printing parameters. Their real geometry was assessed via micro-computed tomography (μ-CT), revealing deviations from nominal shapes. Thermographic tests using a laser heat source (≈40 W/cm2) were conducted to examine the detectability of these defects in the highly diffusive material AlSi10Mg. Results highlight both the limitations and potential of thermography as a cost- and time-effective alternative to μ-CT for quantitative inspection.