Dr. Matthew Harding Profile

Dr. Matthew Harding

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Proceedings Article | 19 April 2022 Presentation + Paper

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, 120480M (2022) https://doi.org/10.1117/12.2614701

KEYWORDS: Ultrasonics, Additive manufacturing, Waveguides, Finite element methods, Defect detection, Phased arrays, Wave propagation, Optical microscopy, Manufacturing, Velocity measurements

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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.

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