Remote Ultrasonic Imaging of a Wire Arc Additive Manufactured Ti-6AI-4V Component using Laser Induced Phased Array

Lukács, Péter; Davis, Geo; Stratoudaki, Theodosia; Williams, Stewart; MacLeod, Charles N.; Gachagan, Anthony

doi:10.1109/i2mtc50364.2021.9459823

Cited by 8 publications

(4 citation statements)

References 20 publications

(29 reference statements)

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“… Intentionally introduced defects (D1, D2 and D3 in Figure 3 ) are detected by means of TFM image of the component using ultrasonic longitudinal waves [ 25 ]. …”

Section: Figurementioning

confidence: 99%

“…They were able to successfully detect most of the defects using a TFM technique. Later, Lukacs et al [ 25 ] adopted Laser-Induced Phased Array (LIPA), full matrix capture data acquisition and a Total Focusing Method (TFM) to inspect a titanium alloy (Ti-6Al-4V) fabricated using plasma arc WAAM. As illustrated in Figure 3 and Figure 4 , they clearly indicate that defects located at a depth of up to 10 mm inside the sample can be found offline by means of high-quality images.…”

Section: Introductionmentioning

confidence: 99%

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A Review of Non-Destructive Testing (NDT) Techniques for Defect Detection: Application to Fusion Welding and Future Wire Arc Additive Manufacturing Processes

et al. 2022

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In Wire and Arc Additive Manufacturing (WAAM) and fusion welding, various defects such as porosity, cracks, deformation and lack of fusion can occur during the fabrication process. These have a strong impact on the mechanical properties and can also lead to failure of the manufactured parts during service. These defects can be recognized using non-destructive testing (NDT) methods so that the examined workpiece is not harmed. This paper provides a comprehensive overview of various NDT techniques for WAAM and fusion welding, including laser-ultrasonic, acoustic emission with an airborne optical microphone, optical emission spectroscopy, laser-induced breakdown spectroscopy, laser opto-ultrasonic dual detection, thermography and also in-process defect detection via weld current monitoring with an oscilloscope. In addition, the novel research conducted, its operating principle and the equipment required to perform these techniques are presented. The minimum defect size that can be identified via NDT methods has been obtained from previous academic research or from tests carried out by companies. The use of these techniques in WAAM and fusion welding applications makes it possible to detect defects and to take a step towards the production of high-quality final components.

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“… Intentionally introduced defects (D1, D2 and D3 in Figure 3 ) are detected by means of TFM image of the component using ultrasonic longitudinal waves [ 25 ]. …”

Section: Figurementioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

A Review of Non-Destructive Testing (NDT) Techniques for Defect Detection: Application to Fusion Welding and Future Wire Arc Additive Manufacturing Processes

et al. 2022

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“…Moreover, recently, laser-induced phased arrays (LIPAs) improve the low signal amplitudes of conventional LU methods in the non-destructive and thermoelastic regimes. In this regard, Lukacs et al 67 used LIPA of 68 elements for ultrasonic imaging of wire arc additive manufactured Ti-6AI-4 V component that led to the production of ultrasonic images with excellent quality which accurately detected and showed defects up to depths of 10 mm from the inspection surface. In addition, high-frequency PAUT techniques can be utilized to accurately capture any defects of AM products, Fayazbakhsh et al 68 employed high frequency (PAUT) non-destructive method for inspection of samples produced by one of the AM methods known as fused filament fabrication and one single scan produced high-resolution images clearly showing the raster angles.…”

Section: Casting Phased Array Ultrasonic Testingmentioning

confidence: 99%

Ultrasonic and phased-array inspection in titanium-based alloys: A review

Shi

Ebrahimi

Zhou

et al. 2022

Proceedings of the Institution of Mechanical Engineers, Part E:

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Ultrasonic testing procedures are among the most extensively used techniques in non-destructive testing and non-destructive evaluation systems. Meanwhile, phased array inspection or phased-array ultrasonic testing techniques as a well-known type of ultrasonic testing in advanced non-destructive testing systems are utilized in numerous applications, including oil and gas, medical imaging applications, railway, automotive, marine, and aviation industries. Phased-array ultrasonic testing-based methods can also be used in a variety of weld inspections, bond testing, thickness profiling, flaw detections, corrosion inspections, and in-service crack detection. The rapidity, safety, easiness, affordable price, and accurate visualization of phased array in measuring the defect characteristics such as size, shape, depth, and orientation allow its wide usage and even as a substitute for other inspection methods like radiographic methods. In phased array methods, more than one sound wave is employed to enhance the reliability and flexibility of inspection through the operation of several transducer assemblies, involving 16 to 256 small individual elements. Titanium having many desirable properties like high strength to weight ratio found many industrial applications, which highly necessitates its persistent inspection. For this aim, the present study focuses on the application of the phased-array ultrasonic testing technique for inspecting Ti components specifically in additive manufacturing, welding inspections, and defect detection of complex geometries and composites. Moreover, modern applications and improved computation methods are discussed. The development of phased-array ultrasonic testing inspection systems, particularly high throughput and efficient in situ and mobile equipment, and new computation methods will open new horizons toward the highly sophisticated inspection procedures.

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“…Previously, LIPAs have successfully imaged side drilled holes representing defects in components [7,8]. However, the TFM images generated using LIPA data contained a region saturated by the surface acoustic wave (SAW).…”

Section: Introductionmentioning

confidence: 99%

Surface Acoustic Wave Suppression for Near-Surface Defect Imaging Using Laser Induced Phased Arrays

Davis

Fuwaires

Kamintzis

et al. 2022

2022 49th Annual Review of Progress in Quantitative Nondestructive Evaluation

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Laser induced phased arrays (LIPAs) offer fast and efficient remote ultrasonic imaging for processes operating in extreme environments and restricted access such as additive manufacturing and welding. In this work, LIPAs are synthesized in the non-destructive thermoelastic regime using an 8 ns pulsed 1064 nm generation laser and a 532 nm continuous wave detection laser. The acquired Full Matrix data is post-processed using the Total Focusing Method (TFM) to image near-surface side-drilled holes inside an Aluminium sample. The images generated, however, contain contribution from the surface acoustic wave (SAW). In laser ultrasonics, SAW is the strongest wave mode generated, and consequently, a region of the image generated is saturated by the SAW arrival (SAW cross-talk). The SAW cross-talk region extends into the sample starting at the scan surface and hence masks any features/defects within this region. This study explores and compares various signal processing techniques such as frequency-wavenumber filtering, phase coherence imaging and amplitude thresholding of ultrasonic signals in order to suppress/remove the SAW cross-talk from the ultrasonic data captured using LIPA for successful imaging of near-surface defects. The mode suppression is achieved by targeting the characteristics of the SAW: its velocity, amplitude and phase. The different methods of wave suppression are compared, and relative merits of each technique are discussed.

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Remote Ultrasonic Imaging of a Wire Arc Additive Manufactured Ti-6AI-4V Component using Laser Induced Phased Array

Cited by 8 publications

References 20 publications

A Review of Non-Destructive Testing (NDT) Techniques for Defect Detection: Application to Fusion Welding and Future Wire Arc Additive Manufacturing Processes

A Review of Non-Destructive Testing (NDT) Techniques for Defect Detection: Application to Fusion Welding and Future Wire Arc Additive Manufacturing Processes

Ultrasonic and phased-array inspection in titanium-based alloys: A review

Surface Acoustic Wave Suppression for Near-Surface Defect Imaging Using Laser Induced Phased Arrays

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