Resonant ultrasound spectroscopy for quality control of geometrically complex additively manufactured components

McGuigan, Samantha; Argüelles, Andrea P.; Obaton, Anne Françoise; Dönmez, Alkan; Rivière, Jacques; Shokouhi, Parisa

doi:10.1016/j.addma.2020.101808

Cited by 20 publications

(12 citation statements)

References 40 publications

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“…Coincidently, one of the original aims of developing additive manufacturing was fabricating customized and complex geometric samples. A reported study [ 92 ] described quality control inspection of metal alloy additive manufactured products with complex shapes ( Figure 18 ). The numerical simulation estimated the resonance modes of the non-flawed sample.…”

Section: Ultrasonic Inspection and Evaluationmentioning

confidence: 99%

A Review of Diagnostics Methodologies for Metal Additive Manufacturing Processes and Products

et al. 2021

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Additive manufacturing technologies based on metal are evolving into an essential advanced manufacturing tool for constructing prototypes and parts that can lead to complex structures, dissimilar metal-based structures that cannot be constructed using conventional metallurgical techniques. Unlike traditional manufacturing processes, the metal AM processes are unreliable due to variable process parameters and a lack of conventionally acceptable evaluation methods. A thorough understanding of various diagnostic techniques is essential to improve the quality of additively manufactured products and provide reliable feedback on the manufacturing processes for improving the quality of the products. This review summarizes and discusses various ex-situ inspections and in-situ monitoring methods, including electron-based methods, thermal methods, acoustic methods, laser breakdown, and mechanical methods, for metal additive manufacturing.

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Section: Ultrasonic Inspection and Evaluationmentioning

confidence: 99%

A Review of Diagnostics Methodologies for Metal Additive Manufacturing Processes and Products

et al. 2021

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“…The behavior of elastic moduli as a function of temperature or magnetic field has been used to study unconventional superconductors, heavy fermion metals, quantum magnets, and other correlated states of matter [1][2][3][4][5][6][7][8][9][10] . Accurate measurements of elastic moduli also allow for precision quality control in manufactured parts, for example in ball bearings used in aeronautics, or monitoring for damage in large-scale steel parts [11][12][13][14] .…”

Section: Introductionmentioning

confidence: 99%

Rapid Method for Computing the Mechanical Resonances of Irregular Objects

Shragai¹,

Theuss²,

Grissonnanche³

et al. 2022

Preprint

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A solid object's geometry, density, and elastic moduli completely determine its spectrum of normal modes. Solving the inverse problem -determining a material's elastic moduli given a set of resonance frequencies and sample geometry -relies on the ability to compute resonance spectra accurately and efficiently. Established methods for calculating these spectra are either fast but limited to simple geometries, or are applicable to arbitrarily shaped samples at the cost of being prohibitively slow. Here, we describe a method to rapidly compute the normal modes of irregularly shaped objects using entirely open-source software. Our method's accuracy compares favorably with existing methods for simple geometries and shows a significant improvement in speed over existing methods for irregular geometries.

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“…Hence, alternative non-destructive volumetric methods are required. Among all of the available non-destructive technologies, resonant ultrasound spectroscopy (RUS) [7][8][9][10] gives the most valuable results-after XCT-to control metallic parts [8,11,12]. RUS inspections are global or whole-body methods able to sort parts based on the analysis of their natural resonant frequencies by comparison to the natural resonant frequencies of parts from the same family or to the modelled natural resonant frequencies.…”

Section: Introductionmentioning

confidence: 99%

Classification of metal PBF-LB parts manufactured with different process parameters using resonant ultrasound spectroscopy

Obaton

Weaver²,

Fayard

et al. 2022

Weld World

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To face the challenges raised by the qualification of metallic additively manufactured (AM) complex shaped and rough finish parts, non-destructive testing (NDT) volumetric methods are required. X-ray computed tomography (XCT) is presently the favored technique; however, alternative methods are needed to overcome the requirement of technical skills and the high cost of the technique. XCT also has limitations regarding the size and density of parts. Here, we propose an easy to use, fast, and efficient global NDT volumetric method based on resonant ultrasound spectroscopy (RUS) which basic principle relies on the comparative analysis of natural resonant frequency spectra of similar parts from the same family, both of which vibrating as free as possible. The methods have already proven to have the ability to sort parts with defects from flawless parts. In the present study, we demonstrate that RUS can also segregate metallic parts manufactured with different AM system process parameters. Eleven sets of three parts were manufactured, using a metal laser-powder bed fusion process, with different wall thicknesses, laser powers, scanning speeds, and scanning strategies. These parts were tested by RUS and then analyzed using the Z-score statistical method. The AM process parameter changes clearly influenced the resonance responses of the parts, and thus, the method is able to classify the different groups of parts according to their process parameters. Hence, the RUS methods can provide industries convenient tools to not only identify defective parts but to also configure AM machine parameters according to the expected and desired material properties.

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Resonant ultrasound spectroscopy for quality control of geometrically complex additively manufactured components

Cited by 20 publications

References 40 publications

A Review of Diagnostics Methodologies for Metal Additive Manufacturing Processes and Products

A Review of Diagnostics Methodologies for Metal Additive Manufacturing Processes and Products

Rapid Method for Computing the Mechanical Resonances of Irregular Objects

Classification of metal PBF-LB parts manufactured with different process parameters using resonant ultrasound spectroscopy

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