A High-Temperature Phased Array Ultrasonic Roller-Probe Designed for Dry-Coupled In-Process Inspection of Wire + Arc Additive Manufactured Components

Mohseni, Ehsan; Vithanage, Randika K. W.; Qiu, Zhen; Javadi, Yashar; Lines, David; MacLeod, Charles N.; Zimermann, Rastislav; Pierce, S. Gareth; Gachagan, Anthony; Ding, Jialuo; Williams, Stewart

doi:10.1115/1.0002292v

Cited by 5 publications

(6 citation statements)

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“…Their 3D acoustic field modeling for both linear and annular PA transducers demonstrated that at various propagating angles and C-scan images, the annular PA probe shows higher accuracy in defect detection compared to linear PA probe. In another study, Mohseni et al 70 inspected the Ti samples produced by the wire plus arc AM method (WAAM) through the PAUT technique. The produced WAAM Ti samples contained some intentional defects, including LoF and keyhole defects.…”

Section: Ultrasonic Pa Inspection Of Titanium-based Alloysmentioning

confidence: 99%

“…(a) The PAUT inspection of a titanium WAAM wall; the TFM results of the WAAM by 10 MHZ and 5 MHZ inspections through (b) LTPA controller (peak NDT, UK) + Bristol brain TFM algorithm and (c) FIToolbox (diagnostic sonar, UK) controller + FITStreamFRD TFM algorithm. 70 …”

Section: Ultrasonic Pa Inspection Of Titanium-based Alloysmentioning

confidence: 99%

“…Their 3D acoustic field modeling for both linear and annular PA transducers demonstrated that at various propagating angles and C-scan images, the annular PA probe shows higher accuracy in defect detection compared to linear PA probe. In another study, Mohseni et al 70 Overall, it is believed that annular phased arrays have significantly superior performance over other phased 91 arrays since they lead to better penetration depths and lateral resolutions without the need for lots of elements. With the same total aperture and focal length, they also lead to improved lateral resolution as compared to a single element focused transducer.…”

Section: Casting Phased Array Ultrasonic Testingmentioning

confidence: 99%

See 2 more Smart Citations

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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Section: Ultrasonic Pa Inspection Of Titanium-based Alloysmentioning

confidence: 99%

Section: Ultrasonic Pa Inspection Of Titanium-based Alloysmentioning

confidence: 99%

“…Their 3D acoustic field modeling for both linear and annular PA transducers demonstrated that at various propagating angles and C-scan images, the annular PA probe shows higher accuracy in defect detection compared to linear PA probe. In another study, Mohseni et al 70 Overall, it is believed that annular phased arrays have significantly superior performance over other phased 91 arrays since they lead to better penetration depths and lateral resolutions without the need for lots of elements. With the same total aperture and focal length, they also lead to improved lateral resolution as compared to a single element focused transducer.…”

Section: Casting Phased Array Ultrasonic Testingmentioning

confidence: 99%

See 1 more Smart Citation

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:

View full text Add to dashboard Cite

show abstract

“…The recent development has also shown a deployment of the high-temperature liquid-filled roller-probe on in-process inspection of multi-pass welds [42]. In this work, a roller-probe is designed for the dry-coupled inspection of large scale WAAM components in order of centimetres/meters [46] but has the potential to be adapted to a variety of large scale additive manufacturing techniques or large structures. The WAAM roller-probe, illustrated in Figure 2, is equipped with a watertight rotary rubber tire and a delay-line, through which the ultrasonic wave generated by the ultrasonic array can propagate.…”

Section: 1: Automated As-built Waam Component Inspectionmentioning

confidence: 99%

Multi-layer ultrasonic imaging of as-built Wire + Arc Additive Manufactured components

Zimermann

Mohseni

Lines

et al. 2021

Additive Manufacturing

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“…Further, the roller-probe technology has also been developed to couple with an as-built surface of WAAM components without the use of liquid couplants [19]. However, when considering the roller-probe inspection approach, new challenges emerged, as the as-built WAAM component features a non-flat and varying surface geometry (in both the scanning and the traverse direction) resulting in high contact forces being required to assure full compliance of the roller-probe tyre to the surface.…”

Section: Introductionmentioning

confidence: 99%

Collaborative Robotic Wire + Arc Additive Manufacture and Sensor-Enabled In-Process Ultrasonic Non-Destructive Evaluation

Zimermann

Mohseni

Vasilev

et al. 2022

Sensors

Self Cite

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The demand for cost-efficient manufacturing of complex metal components has driven research for metal Additive Manufacturing (AM) such as Wire + Arc Additive Manufacturing (WAAM). WAAM enables automated, time- and material-efficient manufacturing of metal parts. To strengthen these benefits, the demand for robotically deployed in-process Non-Destructive Evaluation (NDE) has risen, aiming to replace current manually deployed inspection techniques after completion of the part. This work presents a synchronized multi-robot WAAM and NDE cell aiming to achieve (1) defect detection in-process, (2) enable possible in-process repair and (3) prevent costly scrappage or rework of completed defective builds. The deployment of the NDE during a deposition process is achieved through real-time position control of robots based on sensor input. A novel high-temperature capable, dry-coupled phased array ultrasound transducer (PAUT) roller-probe device is used for the NDE inspection. The dry-coupled sensor is tailored for coupling with an as-built high-temperature WAAM surface at an applied force and speed. The demonstration of the novel ultrasound in-process defect detection approach, presented in this paper, was performed on a titanium WAAM straight sample containing an intentionally embedded tungsten tube reflectors with an internal diameter of 1.0 mm. The ultrasound data were acquired after a pre-specified layer, in-process, employing the Full Matrix Capture (FMC) technique for subsequent post-processing using the adaptive Total Focusing Method (TFM) imaging algorithm assisted by a surface reconstruction algorithm based on the Synthetic Aperture Focusing Technique (SAFT). The presented results show a sufficient signal-to-noise ratio. Therefore, a potential for early defect detection is achieved, directly strengthening the benefits of the AM process by enabling a possible in-process repair.

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A High-Temperature Phased Array Ultrasonic Roller-Probe Designed for Dry-Coupled In-Process Inspection of Wire + Arc Additive Manufactured Components

Cited by 5 publications

References 0 publications

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

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

Multi-layer ultrasonic imaging of as-built Wire + Arc Additive Manufactured components

Collaborative Robotic Wire + Arc Additive Manufacture and Sensor-Enabled In-Process Ultrasonic Non-Destructive Evaluation

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