6533b820fe1ef96bd127a508

RESEARCH PRODUCT

Inspection of additive-manufactured layered components

Michele ScafidiAntonio PantanoDonatella CernigliaJohn Rudlin

subject

FEMNDT inspectionAcoustics and UltrasonicsAdditive manufacturingMechanical engineeringNumerical modelsLaserFinite element methodlaw.inventionSettore ING-IND/14 - Progettazione Meccanica E Costruzione Di MacchinelawLaser ultrasoundDeposition (phase transition)Ultrasonic sensorSensitivity (control systems)InconelLayer (electronics)Laser powder deposition

description

Laser powder deposition (LPD) is a rapid additive manufacturing process to produce, layer upon layer, 3D geometries or to repair high-value components. Currently there is no nondestructive technique that can guarantee absence of flaws in LPD products during manufacturing. In this paper a laser ultrasonic technique for in-line inspection of LPD components is proposed. Reference samples were manufactured from Inconel and machined flaws were created to establish the sensitivity of the technique. Numerical models of laser-generated ultrasonic waves have been created to gain a deeper understanding of physics, to optimize the set-up and to verify the experimental measurements. Results obtained on two sets of reference samples are shown. A proof-of-concept prototype has been demonstrated on some specific deposition samples with induced flaws, that were confirmed by an ultra-high sensitivity X-ray technique. Experimental outcomes prove that typical micro-defects due to the layer-by-layer deposition process, such as near-surface and surface flaws in a single layer deposit, can be detected.

yearjournalcountryeditionlanguage
2015-09-01Ultrasonics
https://doi.org/10.1016/j.ultras.2015.06.001