Fast Ultrasonic Imaging with Total Focusing Method (TFM) for Inspection of Additively Manufactured Polymer Composite Component

Taheri, Hossein; Koester, Lucas W.; Bigelow, Timothy A.; Bond, Leonard J.; Braconnier, Dominique; Carcreff, Ewen; Dao, Gavin; Caulder, Alan; Hassen, Ahmed Arabi

doi:10.32548/rs.2018.009

Cited by 11 publications

(7 citation statements)

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“…Among the NDT methods that must be adapted to WAAM, ultrasonic is routinely used to evaluate welded structures and has proven useful even for high-dimensional structures [1]. The technique with the best use is phased-array ultrasonic testing (PAUT) [34], because it makes use of multi-element transducers that can transmit/receive independently and at different times, allowing a reduction in inspection time and increasing reliability and sensitivity, and can also be applied to high-dimensional structures [35,36]. However, the surface conditions on which the ultrasound test is performed significantly affect the detection of defects, since contact must be established between the ultrasonic and the surface of the component under analysis [37,38].…”

Section: Phased-array Ultrasonic Testingmentioning

confidence: 99%

Non-Destructive Testing Inspection for Metal Components Produced Using Wire and Arc Additive Manufacturing

Serrati

Machado

Oliveira

et al. 2023

Metals

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The wire and arc additive manufacturing (WAAM) process enables the creation and repair of complex structures based on the successive deposition of fed metal in the form of a wire that is fused with an electric arc and then solidifies. The high number of depositions required to create or repair parts increases the likelihood of defect formation. If these are reliably detected during manufacturing, timely correction is possible. However, high temperatures and surface irregularity make inspection difficult. Furthermore, depending on the size, morphology, and location of the defect, the part can be rejected. Recent studies have shown that non-destructive testing (NDT) based on different physical phenomena for the timely, reliable, and customized detection of defects can significantly reduce the rejection rate and allow in-line repair, which consequently reduces waste and rework. This paper presents the latest developments in NDT for WAAM and its limitations and potential.

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Section: Phased-array Ultrasonic Testingmentioning

confidence: 99%

Non-Destructive Testing Inspection for Metal Components Produced Using Wire and Arc Additive Manufacturing

Serrati

Machado

Oliveira

et al. 2023

Metals

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“…Within the ultrasound, the largest issue is the conduction of the projected frequencies through the air and into the part. Due to the layering texture of the produced parts or their surface condition, it is highly difficult to produce a perfectly flush surface mating [45]. The surface irregularities produce "noise", the detection of frequencies due to air, thus reducing the accuracy of the ultrasonic testing technology.…”

Section: Nondestructive Testing After the Processmentioning

confidence: 99%

Failures and Flaws in Fused Deposition Modeling (FDM) Additively Manufactured Polymers and Composites

Baechle-Clayton

Loos

Taheri³

et al. 2022

J. Compos. Sci.

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In this review, the potential failures and flaws associated with fused deposition modeling (FDM) or fused filament fabrication (FFF) 3D printing technology are highlighted. The focus of this article is on presenting the failures and flaws that are caused by the operational standpoints and which are based on the many years of experience with current and emerging materials and equipment for the 3D printing of polymers and composites using the FDM/FFF method. FDM or FFF 3D printing, which is also known as an additive manufacturing (AM) technique, is a material processing and fabrication method where the raw material, usually in the form of filaments, is added layer-by-layer to create a three-dimensional part from a computer designed model. As expected, there are many advantages in terms of material usage, fabrication time, the complexity of the part, and the ease of use in FDM/FFF, which are extensively discussed in many articles. However, to upgrade the application of this technology from public general usage and prototyping to large-scale production use, as well as to be certain about the integrity of the parts even in a prototype, the quality and structural properties of the products become a big concern. This study provides discussions and insights into the potential factors that can cause the failure of 3D printers when producing a part and presents the type and characteristics of potential flaws that can happen in the produced parts. Common defects posed by FDM printing have been discussed, and common nondestructive detection methods to identify these flaws both in-process and after the process is completed are discussed. The discussions on the failures and flaws in machines provides useful information on troubleshooting the process if they happen, and the review on the failures and flaws in parts helps researchers and operators learn about the causes and effects of the flaws in a practical way.

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“…Lopez et al demonstrated the effectiveness of PAUT in detecting defects with diameter ranging from 3 to 5 mm in aluminum wire-arc additive manufacturing (WAAM) components with several degrees of surface finish [12]. Taheri et al adopted PAUT to characterize artificial side drilled holes with diameter of 1 to 2.3 mm existed in an additive manufactured carbon fiber reinforced composite sample [13]. Chabot et al demonstrated the feasibility of PAUT method in detecting defects with diameter ranging from 0.6 to 1 mm in WAAM aluminum alloy parts [14].…”

Section: Introductionmentioning

confidence: 99%

Phased array ultrasonic testing of micro-flaws in additive manufactured titanium block

Wang

et al. 2020

Mater. Res. Express

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While titanium components manufactured by additive manufacturing have been widely used in direct molding of complex components, their performance is strongly affected by existing internal flaws generated in the unique manufacturing process. Thus, how to efficiently and accurately characterize geometrical characteristics of internal flaws is critical for enhancing applications of additive manufactured titanium components. In the present work, an effective non-destructive method by using phased array ultrasonic testing is proposed to characterize sub-millimeter artificial deep bottom holes in additive manufactured TC18 titanium block. Specifically, a phased array ultrasonic testing platform integrated with total focusing method-based post-processing algorithm is established. Flat bottom holes with a diameter of 0.8 mm and a depth of 5.0 mm in 55 mm-sized cube titanium block are detected using both linear and annular array transducers. Experimental results show that preexisting holes can be characterized by both linear and annular transducers, in despite of accompanied high acoustic attenuation. Furthermore, the annular phased array ultrasonic testing has higher detection accuracy and resolution than the linear phased array one, for its stronger capability of sound field focusing. More importantly, the annular phased array ultrasonic testing shows similar high testing accuracy in different relative orientations between forming orientation of the titanium component and sound wave propagation direction. These findings provide an effective strategy for the non-destructive ultrasonic testing of titanium components by additive manufacturing.

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Fast Ultrasonic Imaging with Total Focusing Method (TFM) for Inspection of Additively Manufactured Polymer Composite Component

Cited by 11 publications

References 0 publications

Non-Destructive Testing Inspection for Metal Components Produced Using Wire and Arc Additive Manufacturing

Non-Destructive Testing Inspection for Metal Components Produced Using Wire and Arc Additive Manufacturing

Failures and Flaws in Fused Deposition Modeling (FDM) Additively Manufactured Polymers and Composites

Phased array ultrasonic testing of micro-flaws in additive manufactured titanium block

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