Laser opto-ultrasonic dual detection for simultaneous compositional, structural, and stress analyses for wire + arc additive manufacturing

Ma, Yuyang; Hu, Zhenlin; Tang, Yun; Ma, Shixiang; Chu, Yanwu; Li, Xin; Luo, Wei; Guo, Lianbo; Zeng, Xiaoyan; Lu, Yongfeng

doi:10.1016/j.addma.2019.100956

Cited by 31 publications

(17 citation statements)

References 29 publications

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“…In-situ process monitoring provides information of the process stability and detection of anomalies. Process information may be gathered by data from laser and IR sensors, weld signallers, pyrometers, ultrasound, spectrometers, and charge-coupled device (CCD) cameras to ensure the process quality [ 101 , 102 , 103 ]. Other hardware equipment include clamping fixtures to depress distortion, as well as in-situ or postmachining of the component to obtain a smooth outer- and inner-surface finish [ 104 , 105 , 106 ].…”

Section: Strategies To Mitigate Defects In Waammentioning

confidence: 99%

Review of Aluminum Alloy Development for Wire Arc Additive Manufacturing

et al. 2021

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Processing of aluminum alloys by wire arc additive manufacturing (WAAM) gained significant attention from industry and academia in the last decade. With the possibility to create large and relatively complex parts at low investment and operational expenses, WAAM is well-suited for implementation in a range of industries. The process nature involves fusion melting of a feedstock wire by an electric arc where metal droplets are strategically deposited in a layer-by-layer fashion to create the final shape. The inherent fusion and solidification characteristics in WAAM are governing several aspects of the final material, herein process-related defects such as porosity and cracking, microstructure, properties, and performance. Coupled to all mentioned aspects is the alloy composition, which at present is highly restricted for WAAM of aluminum but received considerable attention in later years. This review article describes common quality issues related to WAAM of aluminum, i.e., porosity, residual stresses, and cracking. Measures to combat these challenges are further outlined, with special attention to the alloy composition. The state-of-the-art of aluminum alloy selection and measures to further enhance the performance of aluminum WAAM materials are presented. Strategies for further development of new alloys are discussed, with attention on the importance of reducing crack susceptibility and grain refinement.

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Section: Strategies To Mitigate Defects In Waammentioning

confidence: 99%

Review of Aluminum Alloy Development for Wire Arc Additive Manufacturing

et al. 2021

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“…Due to material shrinkage and bending causes tensile stress in the top and bottom regions of the wall. Ma et al [120] studied Colegrove et al [121] reported the as-deposited samples produced longitudinal residual stress. This is due to distortion in the sample due to the build-in compressive plastic strain.…”

Section: Residual Stresses In Wire Arc Additive Manufactured Componentsmentioning

confidence: 99%

Assessment of Process, Parameters, Residual Stress Mitigation, Post Treatments and Finite Element Analysis Simulations of Wire Arc Additive Manufacturing Technique

Kumar

Manikandan

2021

Met. Mater. Int.

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Wire arc additive manufacturing (WAAM) technique became an emerging manufacturing technology because of its costeffective in creating large-scale metal parts with moderately high deposition rates. Mainly, WAAM works through the utilization of heat source as an electric arc by melting the metal wire to build the three-dimensional metal parts in a layer-by-layer approach, which may significantly minimize the fabrication costs compared to powder and other additive manufacturing techniques such as laser and electron beam, similarly. This article reviews WAAM processes and methods and gives an exhaustive overview of the residual stresses, microstructures, and material properties of the as-fabricated and post-fabrication treated WAAM components. The typical defects during the fabrication of metal components by the WAAM process are residual stresses, deformity, porosity, and cracking. And also, methods on controlling residual stresses, improving material properties, and effects of post-processing treatments to enhance the part quality fabricated by using the WAAM process are recommended in this review. Finally, the measurement methods of residual stresses in the metal parts and FEA simulations in the WAAM are discussed. FEA simulations provide better insights on moving heat source model, temperature distributions, and residual stresses in the WAAM process. This article concludes that selecting process parameters affects the quality WAAM component during the deposition process. And also, approaches to improving the part quality are proposed. The materials fabrication issues in the WAAM processes were outlined, and the advanced WAMM processes were suggested to obtain high quality and defect-free WAAM parts.

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“…Zhan et al [17] applied laser ultrasound to evaluate the residual stress of AM samples under different heat treatment processes. Ma et al [18] investigated a laser opto-ultrasonic dual detection technology for testing elemental compositions and residual stress of wire + arc additive manufacturing sample. Everton et al [19] inspected a AM Ti-6Al-4V sample with subsurface defects by LUT.…”

Section: Introductionmentioning

confidence: 99%

Laser ultrasonic testing for near-surface defects inspection of 316L stainless steel fabricated by laser powder bed fusion

et al. 2021

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The laser powder bed fusion (L-PBF) method of additive manufacturing (AM) is increasingly used in various industrial manufacturing fields due to its high material utilization and design freedom of parts. However, the parts produced by L-PBF usually contain such defects as crack and porosity because of the technological characteristics of L-PBF, which affect the quality of the product. Laser ultrasonic testing (LUT) is a potential technology for on-line testing of the L-PBF process. It is a non-contact and non-destructive approach based on signals from abundant waveforms with a wide frequency-band. In this study, a method of LUT for on-line inspection of L-PBF process was proposed, and a system of LUT was established approaching the actual environment of on-line detection to evaluate the method applicability for defects detection of L-PBF parts. The detection results of near-surface defects in L-PBF 316L stainless steel parts show that the cracktype defects with a sub-millimeter level within 0.5 mm depth can be identified, and accordingly, the positions and dimensions information can be acquired. The results were verified by X-ray computed tomography, which indicates that the present method exhibits great potential for on-line inspection of AM processes.

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Laser opto-ultrasonic dual detection for simultaneous compositional, structural, and stress analyses for wire + arc additive manufacturing

Cited by 31 publications

References 29 publications

Review of Aluminum Alloy Development for Wire Arc Additive Manufacturing

Review of Aluminum Alloy Development for Wire Arc Additive Manufacturing

Assessment of Process, Parameters, Residual Stress Mitigation, Post Treatments and Finite Element Analysis Simulations of Wire Arc Additive Manufacturing Technique

Laser ultrasonic testing for near-surface defects inspection of 316L stainless steel fabricated by laser powder bed fusion

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