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Structured illumination using high-power diode lasers generates a two-dimensional interference of thermal waves. In addition, the sources and the sample are moving relative to each other. Using different configurations, we investigate the validity of the temporal and spatial superposition principle of the heat diffusion equation for these cases both experimentally and by numerical-analytical modelling. Furthermore, we investigate the potential of this approach for non-destructive testing.
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.
More than 80 representatives of SMEs, industrial companies and research institutes met on September 12 at the workshop "Challenges in Additive Manufacturing: Innovative Materials and Quality Control" at BAM in Adlershof to discuss the latest developments in materials and quality control in additive manufacturing.
In special lectures, researchers, users and equipment manufacturers reported on the latest and future developments in additive manufacturing. Furthermore, funding opportunities for projects between SMEs and research institutions on a national and European level were presented.
Lock-in- and flash thermography are standard methods in active thermography. They are widely used in industrial inspection tasks e.g. for the detection of delaminations, cracks or pores. The requirements for the light sources of these two methods are substantially different. While lock-in thermography requires sources that can be easily and above all fast modulated, the use of flash thermography requires sources that release a very high optical energy in the very short time.
By introducing high-power vertical cavity surface emitting lasers (VCSELs) arrays to the field of thermography a source is now available that covers these two areas. VCSEL arrays combine the fast temporal behavior of a diode laser with the high optical irradiance and the wide illumination range of flash lamps or LEDs and can thus potentially replace all conventional light sources of thermography.
However, the main advantage of this laser technology lies in the independent control of individual array areas. It is therefore possible to heat not only in terms of time, but also in terms of space. This new degree of freedom allows the development of new NDT methods. We demonstrate this approach using a test problem that can only be solved to a limited extent in active thermography, namely the detection of very thin, hidden defects in metallic materials that are aligned vertically to the surface. For this purpose, we generate destructively interfering thermal wave fields, which make it possible to detect defects within the range of the thermal wave field high sensitivity. This is done without pre-treatment of the surface and without using a reference area to depths beyond the usual thermographic rule of thumb.
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.
Among the photothermal methods, full-field thermal imaging is used to characterize materials, to determine thicknesses of layers, or to find inhomogeneities such as voids or cracks. The use of classical light sources such as flash lamps (impulse heating) or halogen lamps (modulated heating) led to a variety of nondestructive testing methods, in particular lock-in and flash-thermography.
In vertical cavity surface emitting lasers (VCSELs), laser light is emitted perpendicular to the surface with a symmetrical beam profile. Due to the vertical structure, they can be arranged in large arrays of many thousands of individual lasers, which allows power scaling into the kilowatt range. Recently, a high-power yet very compact version of such a VCSEL-array became available that offers both the fast timing behavior of a laser as well as the large illumination area of a lamp.
Moreover, it allows a spatial and temporal control of the heating because individual parts of the array can be controlled arbitrarily in frequency, amplitude, and phase. In conjunction with a fast infrared camera, such structured heating opens up a field of novel thermal imaging and testing methods. As a first demonstration of this approach, we chose a testing problem very challenging to conventional thermal infrared testing: The detection of very thin subsurface defects perpendicularly oriented to the surface of metallic samples. First, we generate destructively interfering thermal wave fields which are then affected by the presence of defects within their reach. It turned out that this technique allows highly sensitive detection of subsurface defects down to depths in excess of the usual thermographic rule of thumb, with no need for a reference or surface preparation
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.
Active thermography has been developed into a well-established non-destructive testing method and is used to detect cracks, voids, or material properties. The spatial-temporal structure of the external heating: spatially: planar (e.g., halogen lamp) or local (e.g., focused laser), and temporally: pulsed (e.g., flash lamp) or periodical (e.g., halogen lamp), has led to different testing modalities, as for instance flash and lock-in thermography. In this work, we combine a high-power laser with a spatial light modulator (SLM) allowing us to merge all degrees of freedom into a spatially and temporally controlled heat source. This approach allows us to launch a set of individually controlled and fully coherent high-energy thermal waves into the sample volume. As one possible application, we demonstrate the interference of two phase shifted thermal wave patterns in order to detect the position and depth of hidden defects, which is still a challenging task in thermographic and photothermal techniques. The patterns are positioned with a certain distance and a phase shift of pi to each other, creating an amplitude depletion zone that is centered between them. Now, when a defect is brought into the depletion zone, the destructive interference is disturbed and the defect can be recognized. This approach means that we intentionally exploit the vertical and lateral propagation directions of the thermal waves. In a more general view, controlling simultaneously control of phase and amplitude of a set of thermal waves enables us to have a defined propagation of the thermal wave field within the sample, which means that thermal waves can be controlled almost like acoustical or optical waves. However, in contrast to optical or acoustical waves, thermal waves are highly damped due to the diffusive character of the thermal heat flow and therefore limited in penetration depth in relation to the achievable spatial resolution. Nevertheless, the coherence length of thermal waves can be chosen in the mm-range for modulation frequencies below 10 Hz which is perfectly met by present SLM technology. Eventually, this offers the opportunity to transfer known technologies from wave shaping techniques to thermography methods and to exploit the possibilities of coherent thermal wave shaping.
For the last 20 years active thermography has developed into a standard method in non-destructive material testing. It has become possible to detect defects such as cracks, voids, or even material inhomogeneities. Until now, it is still difficult to quantify subsurface or hidden defects in size due to the diffusive nature of heat flow within a solid. Facing this issue, lockin thermography and other photothermal techniques have been established. They are based on exciting a sample periodically (e.g. with a halogen lamp), causing a controlled periodical heat flow and thereby representing strongly damped thermal waves. These techniques make use of interference and reflection of thermal waves which allow enhancing depth resolution.
So far, only the temporal component of the light source was modified to achieve a defined vertical heat flow – In contrast, we propose a novel technique in which we are able to control both: time and space. This technique enables us to exploit the possibilities of coherent thermal wave shaping. We achieve that by combining a spatial light modulator (SLM) with a high power laser. This approach allows us to launch a set of individually controlled and fully coherent high energy thermal waves into the sample volume. That means, we intentionally use wave propagation throughout the sample’s material in both - vertical and lateral direction.
As one possible application, we use a thermal waves’ interference effect of two phase shifted wave patterns to detect the position of hidden defects. The wave patterns are positioned with a certain distance and a 180° phase shift to each other creating an amplitude depletion zone right in the middle of the two patterns. When a defect is brought unsymmetrically into the depletion zone, the lateral heat flow is disturbed. If the sample is now moved through the depletion zone, a defect can be easily characterized. Exciting periodically while controlling simultaneously phase and amplitude enables us to have a defined thermal wave propagation throughout the sample which means thermal waves can be controlled almost like acoustical or optical waves. This offers the opportunity to transfer known technologies from wave shaping techniques to thermography methods.