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APRIL 2022 Volume 80 • Number 4 JOURNAL STAFF PUBLISHER: Neal J. Couture, CAE DIRECTOR OF PUBLICATIONS: Toni Kervina EDITOR: Jill Ross ASSISTANT EDITOR: Cara Markland PRODUCTION MANAGER: Joy Grimm GRAPHIC DESIGNER/ ILLUSTRATOR: Synthia Jester ASNT MEDIA & EVENT SALES Holly Klarman, MCI Group: holly.klarman@wearemci.com 1-410-584-8576 TECHNICAL EDITOR John Z. Chen, KBR ASSOCIATE TECHNICAL EDITORS John C. Aldrin, Computational Tools Sreenivas Alampalli, Stantec Ali Abdul-Aziz, Kent State University Narendra K. Batra, Naval Research Laboratory (retired) Trey Gordon, SpaceX Dietmar Henning, Level III Service LLC Cara A.C. Leckey, NASA Langley Research Center Mani Mina, Iowa State University William E. Mooz, Met-L-Chek Co. Ehsan Dehghan-Niri, New Mexico State University Yi-Cheng (Peter) Pan, Emerson Inc. Anish Poudel, Transportation Technology Center Inc. Donald J. Roth, Roth Technical Consulting LLC Ram P. Samy, Birring NDE Center Inc. Steven M. Shepard, Thermal Wave Imaging Ripi Singh, Inspiring Next Surendra Singh, Honeywell Roderic K. Stanley, NDE Information Consultants Mike C. Tsao, University of Connecticut – Avery Point Lianxiang Yang, Oakland University Reza Zoughi, Iowa State University CONTRIBUTING EDITORS Bruce G. Crouse, Inspection Services Huidong Gao, Pemex Saptarshi Mukherjee, Lawerence Livermore National Laboratory UPFRONT | SCANNER PARADIGM SHIFTS IN ADDITIVE MANUFACTURING Additive manufacturing (AM), synonymous with 3D printing, has revolution- ized manufacturing and reinvigorated various economic sectors (especially aerospace), largely due to its design freedom, reduced costs and lead time, and Industry 4.0 integrations. Despite these successes, business and strategic (supply chain) challenges need to be addressed before it is widely adopted within aviation. Given that 3D-printed aircraft parts are used in systems today, AM industrialization is far from simply “hype.” However, there are issues that require additional attention, including: understanding the complex process physics tuning the materials state concurrently designing parts and materials consistent product integrity and quality assurance universally adopted standards and government approval/ regulations process and data management and supply chain strategy agile scalability limitations building large as well as complex sized titanium and nickel alloy parts limited multi-material capabilities to build a multifunctional part dealing with cybersecurity With respect to the process and materials state, exciting work is ongoing. For example, sophisticated experiments at beam lines are permitting the study of complex dynamics at the micro scale, providing new insights into the AM process. There are efforts to control the materials state (microstruc- ture, texture, residual stress, and defects) through fine-tuning process param- eters and composition, while new integrated models have been developed that promise to accelerate materials development and enable qualification strategies. These support a future of a voxel-by-voxel and part-by-part valida- tion of the material and expected local properties, leading to new qualifica- tion and certification strategies by the appropriate organizations. The promise of tailoring materials state using key process parameters is possible only when we can exploit the AM digital thread and network connectivity. Increasingly, AM systems are designed to connect with Industry 4.0 systems, such as the Internet of Things, cyber-physical systems, and cloud computing. These capabilities enable digital manufacturing systems, yet also present opportunities for cyberattacks. Artificial intelligence (AI) and machine learning (ML) may offer solutions to the inevitable cyberattacks for both the original equipment manufacturer and the supply base. There are exam- ples where a private or public customer has mandated a degree of cyber- security for Industry 4.0 suppliers. While much of AM’s progress today is Edisonian, new hardware and ML could eventually give 3D printers “eyes” (machine vision) and “brains” (closed-looped feedback) to evolve more rapidly. Thus, AM in conjunction with Industry 4.0 presents compelling business opportunities. Through this special issue of Materials Evaluation, we reach out to the industry to embrace the paradigm shift in AM and thereby help the customer supply chain stay ahead of the curve. SURENDRA SINGH FOCUS ISSUE CO-EDITOR HONEYWELL AEROSPACE, SURENDRA.SINGH@HONEY WELL.COM PETER COLLINS FOCUS ISSUE CO-EDITOR IOWA STATE UNIVERSITY, PCOLLINS@IASTATE.EDU A P R I L 2 0 2 2 • M A T E R I A L S E V A L U A T I O N 7