Ultrasonic inspection of additively manufactured metallic components using bulk and guided waves

A. Allam; O. Alfahmi; H. Patel; C. Sugino; M. Harding; M. Ruzzene; A. Erturk

doi:10.1117/12.2614701

19 April 2022 Ultrasonic inspection of additively manufactured metallic components using bulk and guided waves

A. Allam, O. Alfahmi, H. Patel, C. Sugino, M. Harding, M. Ruzzene, A. Erturk

Proceedings Volume 12048, Health Monitoring of Structural and Biological Systems XVI; 120480M (2022) https://doi.org/10.1117/12.2614701
Event: SPIE Smart Structures + Nondestructive Evaluation, 2022, Long Beach, California, United States

Abstract

Additive manufacturing (AM) of metallic components allows for the fabrication of functional metallic components with complex geometries. During AM, unexpected variations in the process parameters may lead to microscale defects which compromise the product functionality. We investigate the use of phased array and guided wave ultrasonic testing as cost-effective and safe quality assurance techniques to detect typical defects generated in selective laser melting (SLM) components. In a typical SLM process, a powdered material is deposited layer by layer then fused together using a laser source to create the desired part geometry. A variation in the laser power or speed can lead to lack-of-fusion or gas porosity defects which might not be detectable during manufacturing. In this work, typical defects are generated in SLM components with thick and thin geometries by deliberately reducing the laser power below the normal values at prespecified locations of the AM samples. The density and shape of the generated defects are first identified using X-ray computed tomography and optical microscopy. A phased array ultrasonic testing probe is then used for imaging pin shaped defects in thick rectangular components. The defect images are also compared to that obtained from numerical simulations using the finite element method. Partially fused defects down to 0.25 mm diameter are detected using this approach. Additionally, a scanning laser Doppler vibrometer is used to image guided waves generated by piezoelectric transducers bonded to thin SLM components. The guided waves are used to detect powder filled cylindrical defects down to 1 mm in size.

Conference Presentation

Citation Download Citation

A. Allam, O. Alfahmi, H. Patel, C. Sugino, M. Harding, M. Ruzzene, and A. Erturk "Ultrasonic inspection of additively manufactured metallic components using bulk and guided waves", Proc. SPIE 12048, Health Monitoring of Structural and Biological Systems XVI, 120480M (19 April 2022); https://doi.org/10.1117/12.2614701

ACCESS THE FULL ARTICLE

INSTITUTIONAL
Select your institution to access the SPIE Digital Library.

SELECT YOUR INSTITUTION

PERSONAL
Sign in with your SPIE account to access your personal subscriptions or to use specific features such as save to my library, sign up for alerts, save searches, etc.

PERSONAL SIGN IN

No SPIE Account? Create one

PURCHASE THIS CONTENT

SUBSCRIBE TO DIGITAL LIBRARY

50 downloads per 1-year subscription

Members: $195

Non-members: $335 ADD TO CART

25 downloads per 1 - year subscription

Members: $145

Non-members: $250 ADD TO CART

PURCHASE SINGLE ARTICLE

Includes PDF, HTML & Video, when available