Ultrasonic phased array inspection of a Wire + Arc Additive Manufactured (WAAM) sample with intentionally embedded defects

Javadi, Yashar; MacLeod, Charles N.; Pierce, S. Gareth; Gachagan, Anthony; Lines, David; Mineo, Carmelo; Ding, Jialuo; Williams, Stewart; Vasilev, Momchil; Mohseni, Ehsan; Su, Riliang

doi:10.1016/j.addma.2019.100806

Cited by 47 publications

(26 citation statements)

References 25 publications

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“…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]. Javadi et al utilized PAUT to characterize sizes of intentionally embedded tungsten carbide balls in WAAM steel specimen [15,16]. Taheri et al performed finite element simulation of PAUT verified by experiments to measure flat bottom holes in additive manufacturing SS17 4PH steel samples [17].…”

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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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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“…Therefore, if post-processing can be minimized, the productivity of the WAAM process will be increased. The productivity of the WAAM process is evaluated using the buy-to-fly (BTF) ratio to include post-processing [7,8]. The BTF ratio is the proportion of the quantity of raw materials removed for the final shape of the product and the quantity of raw materials supplied.…”

Section: Introductionmentioning

confidence: 99%

Optimization of Cold Metal Transfer-Based Wire Arc Additive Manufacturing Processes Using Gaussian Process Regression

Lee¹

2020

Metals

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Wire and arc additive manufacturing (WAAM) is among the most promising additive manufacturing techniques for metals because it yields high productivity at low raw material costs. However, additional post-processing is required to remove redundant surface material from components manufactured by the WAAM process, and thus the productivity decreases. To increase productivity, multi-variable process parameters need to be optimized, including thermo-mechanical effects caused by high deposition rates. When the process is modeled, deposit shape and productivity are challenging to quantify due to uncertainty in multiple variables of the complicated WAAM process. Therefore, we modeled the WAAM process parameters, including uncertainties, using a Gaussian process regression (GPR) method, thus allowing us to develop a WAAM optimization model to improve both productivity and the quality of the deposit shape. The accuracy of the optimized output was verified through a close agreement with experimental values. The optimized deposited material had a wide effective area ratio, small height differences, and near 90° deposition angle, highlighting the usefulness of the GPR model approach to deposit nearly ideal material shapes.

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“…With the development of piezoelectric materials and computers, phased array technology has also gradually been applied to industrial inspection, and has made considerable development and extensive applications in the nuclear industry, aerospace, oil and gas pipelines, and other fields [7]. The total focusing method (TFM) uses full array acquisition, which means that a single array element excites all array elements to receive, and each array element sequentially fires until all the combination of excitation and reception is used to obtain complete detection information.…”

Section: Introductionmentioning

confidence: 99%

Optimal Design of Sparse Array for Ultrasonic Total Focusing Method by Binary Particle Swarm Optimization

et al. 2020

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Ultrasonic phased array technology is used in various fields. Traditional full phased arrays place elements in every position of a uniform lattice with half-wavelength spacing between the lattice points, so the hardware cost is very high. This paper introduces an automatically method to sparsify the full array method with well-controlled sidelobes and the main lobe. By calculating one-dimensional phased array patterns that can reflect phased array performance, the binary particle swarm optimization (BPSO) algorithm is used to optimize the array layout. The method initialized form full array and decreased several elements step by step, then, a sparse array with comprehensive acoustic performance close to the reference full array is obtained. By applying the proposed method to the sparse array design of total focusing method (TFM), the simulation results indicate that the proposed sparse total focusing method can greatly increase computational efficiency while providing significantly higher image quality. The BPSO can provide effective optimization design for sparse arrays. INDEX TERMS Binary particle swarm optimization, sparse array, total focusing method, ultrasonic phased array.

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Ultrasonic phased array inspection of a Wire + Arc Additive Manufactured (WAAM) sample with intentionally embedded defects

Cited by 47 publications

References 25 publications

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

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

Optimization of Cold Metal Transfer-Based Wire Arc Additive Manufacturing Processes Using Gaussian Process Regression

Optimal Design of Sparse Array for Ultrasonic Total Focusing Method by Binary Particle Swarm Optimization

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