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Organisationseinheit der BAM
BAM ensures and represents high standards for safety in technology and chemistry. Additive manufacturing (AM) changes the requirements for conventional non-destructive testing (NDT) as new processes of defect creation occur. Especially in safety critical areas, such as aerospace and automotive, new manufacturing processes and materials always require reliability tests and new standards which is a big challenge for NDT.
Photothermal imaging is commonly used for the characterization of material properties, the determination of layer thicknesses or the detection of inhomogeneities such as voids or cracks. For this purpose, the solid specimen is externally heated, e.g. by using a light source. The resulting transient heat flows interact with the inner structures of the specimen, which in turn is measured as a transient temperature distribution at the surface.
Novel array-shaped, high-power laser light sources allow to control the heating of the surface arbitrarily, both temporally and spatially. This enables us to shape the heat flows within the material in a very specific way. In a first application, we demonstrate how to apply destructively interfering thermal wave fields in order to detect subsurface defects with a very high sensitivity. A similar technique, although originating from a very different physical domain, is already in use for medical 3D imaging showing the high potential of this approach.
Within the field of optically excited thermography, full-field thermal imaging is used to characterize materials, to determine thicknesses of layers or to find inhomogeneities such as voids or cracks. Classical light sources, such as flash lamps (impulse heating) or halogen lamps (modulated heating), are hereby specifically used. This has led to the different testing methods lock-in and flash thermography. The VCSEL array promises to merge these excitation methods.
Vertical Cavity Surface Emitting Lasers (VCSELs) are laser diodes emitting light perpendicular to their surface. Due to the vertical structure they can be arranged in large arrays of many thousand individual lasers and still be controlled like ordinary diode lasers. Recently a high-power albeit very compact version of such a VCSEL-array became available which offers both the fast timing behavior of lasers and large illumination areas. Moreover, it allows a spatial and temporal control of the heating because individual parts of the VCSEL-array can be controlled arbitrarily in frequency, amplitude, and phase.
Although the VCSEL-array has a high potential for a new range of applications, it is too early to proclaim them. As one out of very few labs, we already adopted to this new VCSEL technology and show a thorough characterization and first results obtained with a 2.4 kW device. Specifically, we will discuss
- the linearity between control voltage and optical output
- the minimal pulse duration
- the maximal applicable modulation frequency
- optical projection and its influence on the optical output
- spatial control of the illumination and thermal wave shaping
Our results indicate that a VCSEL-array can be used for conventional impulse (aka flash) thermography whereas pulse duration and power are instantaneously accessible compared to flash lamp excitation. In case of lock-in thermography, we can apply frequencies in excess of 200 Hz without a loss in amplitude or an after glowing of the source, making it attractive for photo thermal applications. Consequently, this means that the VCSEL-array is able to merge the two main excitation methods lock-in and impulse thermography.