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Defects are still common in metal components built with Additive Manufacturing (AM). Process monitoring methods for laser powder bed fusion (PBF-LB/M) are used in industry, but relationships between monitoring data and defect formation are not fully understood yet. Additionally, defects and deformations may develop with a time delay to the laser energy input. Thus, currently, the component quality is only determinable after the finished process.
Here, active laser thermography, a non-destructive testing method, is adapted to PBF-LB/M, using the defocused process laser as heat source. The testing can be performed layer by layer throughout the manufacturing process. The results of the defect detection using infrared cameras are presented for a custom research PBF-LB/M machine. Our work enables a shift from post-process testing of components towards in-situ testing during the AM process. The actual component quality is evaluated in the process chamber and defects can be detected between layers.
Great complexity characterizes Additive Manufacturing (AM) of metallic components via laser powder bed fusion (PBF-LB/M). Due to this, defects in the printed components (like cracks and pores) are still common. Monitoring methods are commercially used, but the relationship between process data and defect formation is not well understood yet. Furthermore, defects and deformations might develop with a temporal delay to the laser energy input. The component’s actual quality is consequently only determinable after the finished process.
To overcome this drawback, thermographic in-situ testing is introduced. The defocused process laser is utilized for nondestructive testing performed layer by layer throughout the build process. The results of the defect detection via infrared cameras are shown for a research PBF-LB/M machine.
This creates the basis for a shift from in-situ monitoring towards in-situ testing during the AM process. Defects are detected immediately inside the process chamber, and the actual component quality is determined.
Austenitic stainless steel welds as well as dissimilar metal welds with nickel alloy filler material, used in safety relevant parts of nuclear power plants, still challenge the ultrasonic inspection. The weld material forms large oriented grains which lead on the one hand to high sound scattering and on the other hand – to inhomogeneity and to the acoustic anisotropy of the weld structure. The ultrasonic wave fronts propagate not linearly, as in ferritic weld joints, but along the curves, which depend on the specific grain structure of the weld. Due the influence of these phenomena, it is difficult to analyze the inspection results and to classify the ultrasonic indications, which could be both from the weld geometry and from the material defects. A correct flaw sizing is not possible.
In an ongoing research project, different techniques to improve the reliability of ultrasonic testing at these kinds of welds are investigated. In a first step (in the previous research project) two ultrasonic inspection techniques were developed and validated on plane test specimens with artificial and realistic flaws. In the ongoing project, these techniques are applied to circumferential pipe welds with longitudinal and transverse flaws.
The technique developed at the Federal Institute for Materials Research and Testing (BAM) in Germany uses a combination of ray tracing and synthetic aperture focusing technique (SAFT). To investigate the unknown grain structure, the velocity distribution of weld-transmitting ultrasound waves is measured and used to model the weld by ray tracing.
The second technique, developed at the Fraunhofer Institute for Nondestructive Testing (IZFP) in Germany, uses Sampling Phased Array (Full Matrix Capture) combined with the reverse phase matching (RPM) and the gradient elastic constant descent algorithm (GECDM). This inspection method is able to estimate the elastic constants of the columnar grains in the weld and offers an improvement of the reliability of ultrasonic testing through the correction of the sound field distortion. The unknown inhomogeneity and anisotropy are investigated using a reference indication and the special optimization algorithm.
Both reconstruction techniques give quantitative inspection results and allow the defect sizing. They have been compared to conventional ultrasonic testing with techniques, which are state of the art for components in nuclear power plants. The improvement will be quantified by the comparison of the probability of detection (POD) of each technique.
Ultrasonic echo testing is widely used in non-destructive testing to investigate concrete structures as well as to locate built-in components or inhomogeneities. Currently, Synthetic Aperture Focusing Technique algorithms (SAFT) are used for imaging. These algorithms are highly developed but have some limitations. It is not possible to image the lower boundary of tendon ducts or vertical reflectors. We adopted a geophysical imaging technique, the Reverse Time Migration (RTM), to non-destructive testing in order to improve the imaging of complicated structures in concrete. By using the entire wavefield there are fewer limitations compared to SAFT.
In a first step, simulations for polyamide and concrete structures were performed by using a 2D acoustic finite difference code. The simulations were followed by experiments at a polyamide specimen. Here we were able to determine shape and size of boreholes with a sufficient accuracy. After these successful tests we carried out experiments at a reinforced concrete foundation slab. The reconstruction of the structure of the lower boundary of the slab was improved and vertical reflectors inside the slab were imaged clearly. These tests on polyamide and concrete showed that RTM is a step forward for ultrasonic testing. However we observed migration artifacts and difficulties in imaging 3D structures.
In a second step we implemented a 2D elastic RTM code, since for our ultrasonic measurements elastic waves are emitted. The modeling code is included in the Madagascar software package. The required computing power for performing elastic RTM is significantly high. Thus we need appropriate computer hardware to obtain meaningful results within an adequate time frame. Using our hardware RTM of an ultrasonic data set takes far too long (3 months).
We applied the elastic code to ultrasonic data acquired on a concrete specimen which contains vertical reflectors. A comparison of the acoustic RTM results with those obtained by elastic RTM showed an improvement in the image quality.
Future work includes the analysis of RTM artifacts and the expansion of the algorithm to three dimensions. Another topic to be addressed is to how to account for the size of the ultrasonic transducer arrays which we are using.