Laser Induced Phased Arrays (LIPA) to detect nested features in additively manufactured components

Pieris, Don; Stratoudaki, Theodosia; Javadi, Yashar; Lukács, Péter; Catchpole-Smith, Sam; Wilcox, Paul D.; Clare, Adam T.; Clark, Matt

doi:10.1016/j.matdes.2019.108412

Cited by 49 publications

(10 citation statements)

References 24 publications

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“…Recently, the method was used to identify crystallographic textures, initially in an offline scenario but potentially also deployable for in-situ process monitoring (Dryburgh et al, 2019). The detection of artificial cavities of only 0.2 mm in size has recently been demonstrated using laser-induced phased arrays, although the response is not equal throughout the volume (Pieris et al, 2020). All these aforementioned techniques are technologically challenging in some ways, either in hardware or in machine learning required.…”

Section: Introductionmentioning

confidence: 99%

Monitoring of Laser Powder Bed Fusion by Acoustic Emission: Investigation of Single Tracks and Layers

et al. 2021

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Quality concerns in laser powder bed fusion (L-PBF) include porosity, residual stresses and deformations during processing. Single tracks are the fundamental building blocks in L-PBF and their shape and geometry influence subsequent porosity in 3D L-PBF parts. The morphology of single tracks depends primarily on process parameters. The purpose of this paper is to demonstrate an approach to acoustic emission (AE) online monitoring of the L-PBF process for indirect defect analysis. This is demonstrated through the monitoring of single tracks without powder, with powder and in layers. Gas-borne AE signals in the frequency range of 2–20 kHz were sampled using a microphone placed inside the build chamber of a L-PBF machine. The single track geometry and shape at different powder thickness values and laser powers were studied together with the corresponding acoustic signals. Analysis of the acoustic signals allowed for the identification of characteristic amplitudes and frequencies, with promising results that support its use as a complementary method for in-situ monitoring and real-time defect detection in L-PBF. This work proves the capability to directly detect the balling effect that strongly affects the formation of porosity in L-PBF parts by AE monitoring.

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Section: Introductionmentioning

confidence: 99%

Monitoring of Laser Powder Bed Fusion by Acoustic Emission: Investigation of Single Tracks and Layers

et al. 2021

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“…Lasers can be deployed remotely and used in places of restricted access, don't require coupling to the test object and can adapt to complex shapes [5]. These features have made laser ultrasound attractive for NDT inspection of additive manufactured components [6]- [9]. Techniques such as Synthetic Aperture Focusing Technique [6] and B-scan imaging [7] have been successfully demonstrated on additively manufactured components; the former in ablative regime, causing surface damage, but achieving higher signal amplitudes, while the latter in the lower amplitude, truly non-destructive thermoelastic regime.…”

Section: Introductionmentioning

confidence: 99%

“…In a recent publication, LIPAs have demonstrated successful detection and characterisation of nested features in an Aluminium AM component made using Selective Laser Melting (SLM). The cylindrical features were as small as 0.2mm in diameter and were located as deep as 26 mm below the inspection surface [9].…”

Section: Introductionmentioning

confidence: 99%

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

Lukács

Davis

Stratoudaki

et al. 2021

2021 IEEE International Instrumentation and Measurement Technology Conference (I2MTC)

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Additive manufacturing (AM) has been revolutionizing the manufacturing industry due to its ability to significantly reduce waste and produce components with intricate shapes. Laser Ultrasonics (LU) is a non-contact and couplant free method to generate and detect ultrasound. LU can accommodate complex component shapes; thus, it has the potential to provide a reliable in-process inspection method for AM components. In recent years the development of Laser Induced Phased Arrays (LIPAs) helped overcome the inherently low signal amplitudes of LU at the non-destructive, thermoelastic regime. In this paper, the Full Matrix Capture data acquisition method is used and a LIPA of 68 elements is synthesized in post processing. The Total Focusing Method imaging algorithm is applied for ultrasonic imaging. The technique is demonstrated on a highly scattering titanium alloy Wire Arc Additive Manufactured (WAAM) component producing high quality ultrasonic images, accurately imaging defects at depths up to 10mm below the inspection surface.

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“…The advantage of capturing the Full Matrix is that it can be post processed in a range of algorithms. Cross-sectional imaging using 1D LIPAs have been successfully demonstrated on additively manufactured components created using Wire+Arc Additive Manufacturing (WAAM) [6] and Selective Laser Melting [7], detecting cylindrical defects with a diameter of 0.25 mm in the latter case.…”

Section: Introductionmentioning

confidence: 99%

Remote, Volumetric Ultrasonic Imaging of Defects Using Two-Dimensional Laser Induced Phased Arrays

Lukács

Davis

Stratoudaki

et al. 2021

2021 48th Annual Review of Progress in Quantitative Nondestructive Evaluation

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Manufacturing processes, such as welding and additive manufacturing, take place at high temperatures and extreme environments that offer significant challenges to conventional non-destructive testing methods. Laser Induced Phased Arrays (LIPAs) have evolved as a promising testing method for the aforesaid applications due to its remote and couplant free operation. Contrary to transducer-based phased arrays, LIPAs are synthesized in post-processing by scanning the generation and detection lasers. The data from one-dimensional (1D) phased arrays are used to produce two-dimensional (2D), cross-sectional images, whereas the data from two-dimensional phased arrays generate three-dimensional (3D) images, thus providing more information on defect characterization. In this work, two-dimensional (2D) LIPAs are synthesized in the non-destructive thermoelastic regime using lasers for ultrasonic generation and detection, in order to image defects at different depths inside an aluminum sample. The acquired data is processed using the Total Focusing Method (TFM) algorithm to obtain volumetric images representing the interior of the sample. A 3D finite element (FE) model is also developed to support the experiments.

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Laser Induced Phased Arrays (LIPA) to detect nested features in additively manufactured components

Cited by 49 publications

References 24 publications

Monitoring of Laser Powder Bed Fusion by Acoustic Emission: Investigation of Single Tracks and Layers

Monitoring of Laser Powder Bed Fusion by Acoustic Emission: Investigation of Single Tracks and Layers

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

Remote, Volumetric Ultrasonic Imaging of Defects Using Two-Dimensional Laser Induced Phased Arrays

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