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

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

doi:10.1016/j.addma.2021.102398

Cited by 17 publications

(7 citation statements)

References 45 publications

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“…After the completion of the in-process NDE, the ultrasound data were processed using a SAFT-TFM algorithm described in [22]. The TFM frames (B-Scan) were computed for a 25 mm × 19 mm region at 6 pixels/mm resolution, which is compatible with the 2 dB Amplitude Fidelity criterion of ASME V [36].…”

Section: Ultrasound Data Post-processing: Tfm Imaging and C-scanmentioning

confidence: 99%

“…Owing to the novel WAAM dry-coupled roller-probe ultrasound NDE concept, the research has presented a possibility to detect Lack of Fusion (LoF) defects as small as 5 × 0.5 × 0.5 mm (width, length and height), through an as-built surface of the WAAM wall [22]. The ultrasound data acquisition called Full Matrix Capture (FMC) enabled the collection of raw time-domain data without consideration of any refractive boundaries or couplant conditions as the imaging was executed at the post-processing stage [23].…”

Section: Introductionmentioning

confidence: 99%

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

Zimermann

Mohseni

Vasilev

et al. 2022

Sensors

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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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Section: Ultrasound Data Post-processing: Tfm Imaging and C-scanmentioning

confidence: 99%

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

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“…wherein ( C, ρ) is given by (51). In this setting, one may show that the Cauchy data affiliated with w = w i − w i vanish on…”

Section: Design Of Imaging Functionalsmentioning

confidence: 99%

“…Existing imaging solutions mostly rely on (a) significant assumptions on the nature of wave motion in the background, or (b) optimization-based full-waveform inversion. Expedited data processing in (a), which underpins the prevalent time-of-flight methods in laserultrasonic imaging [51,33], is made possible by leveraging the propagating modes of an isotropic elastic solid. This leads to significant errors in heterogeneous and anisotropic solids where multiple scattering generates remarkable wave dispersion and attenuation.…”

Section: Introductionmentioning

confidence: 99%

Ultrasonic imaging in highly heterogeneous backgrounds

Pourahmadian,

Haddar

2022

Preprint

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This work formally investigates the differential evolution indicators as a tool for ultrasonic tracking of elastic transformation and fracturing in randomly heterogeneous solids. Within the framework of periodic sensing, it is assumed that the background at time t • contains (i) a multiply connected set of viscoelastic, anisotropic, and piece-wise homogeneous inclusions, and (ii) a union of possibly disjoint fractures and pores. The support, material properties, and interfacial condition of scatterers in (i) and (ii) are unknown, while elastic constants of the matrix are provided. The domain undergoes progressive variations of arbitrary chemomechanical origins such that its geometric configuration and elastic properties at future times are distinct. At every sensing step t • , t 1 , . . ., multi-modal incidents are generated by a set of boundary excitations, and the resulting scattered fields are captured over the observation surface. The test data are then used to construct a sequence of wavefront densities by solving the spectral scattering equation. The incident fields affiliated with distinct pairs of obtained wavefronts are analyzed over the stationary and evolving scatterers for a suit of geometric and elastic evolution scenarios entailing both interfacial and volumetric transformations. The main theorem establishes the invariance of pertinent incident fields at the loci of static fractures and inclusions between a given pair of time steps, while certifying variation of the same fields over the modified regions. These results furnish a basis for theoretical justification of differential evolution indicators for imaging in complex composites which, in turn, enable the exclusive tomography of evolution in a background endowed with many unknown features.

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“…By manipulating time delays of electrical excitation pulses sent to individual piezoelectric elements in the phased array, ultrasonic phase delays can be induced, allowing resulting beams focussed and steered accordingly [2]. In turn, this has led to the rapid uptake and dependability of PAUT in NDT, in areas such as weld inspection [3], additive manufacturing [4,5], composite testing [6], and non-piezo wave generation such as laser induced phased arrays [7].…”

Section: Introductionmentioning

confidence: 99%

Dual-tandem phased array method for imaging of near-vertical defects in narrow-gap welds

Nicolson

Mohseni

Sumana

et al. 2023

NDT & E International

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

Cited by 17 publications

References 45 publications

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

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

Ultrasonic imaging in highly heterogeneous backgrounds

Dual-tandem phased array method for imaging of near-vertical defects in narrow-gap welds

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