3rd International Workshop on Laser Ultrasound for Metals Laser ultrasound for the evaluation of additive manufactured parts Donatella Cerniglia, Nicola Montinaro donatella.cerniglia@unipa.it
Problem statement and objective Additive manufacturing (AM) technology allows to manufacture or repair metallic components. Micrometric interlayer and intralayer defects are often observed in AM parts. Currently quality is assessed by destructive testing or by computed tomography after the part is completed. Lack of NDT during the AM process is a limit for the industrial breakthroughs. Non-contact and remote inspection would allow integration of NDT system into AM equipment, thus allowing continuous monitoring. Laser ultrasound is evaluated for this purpose. 3rd International Workshop on Laser Ultrasound for Metals
INTRAPID - Innovative Inspection Techniques for Laser Powder Deposition Quality Control Development of three NDT techniques for inspection of parts manufactured by Laser Metal Deposition Consortium: 4 SME and 3 Research organizations from 4 EU Countries. Eddy current Laser Ultrasound Laser Thermography 3rd International Workshop on Laser Ultrasound for Metals
Samples in Inconel 600 Sample 1 Sample 2 3rd International Workshop on Laser Ultrasound for Metals
Laser UT system 3rd International Workshop on Laser Ultrasound for Metals
Experimental results Sample 1 Diameter (µm) Depth (µm) Set 1 - A 550 300 Sample 1 Diameter (µm) Depth (µm) Set 1 - B 450 600 Sample 1 Diameter (µm) Depth (µm) Set 1 C 500 700 Sample 1 Diameter (µm) Depth (µm) Set 2 - A 150 100 Sample 1 Diameter (µm) Depth (µm) Set 2 - B 200* 200 Sample 1 Diameter (µm) Depth (µm) Set 2 - C 100* 100 * hole not observable from the other side of sample
Experimental results Sample 2 Diameter (µm) Depth (µm) EDM1-1 154 135 Sample 2 Diameter (µm) Depth (µm) EDM2-1 170 115 Sample 2 Diameter (µm) Depth (µm) EDM3-1 160 156 Dipartimento di Ingegneria Chimica Sample 2 Gestionale Diameter (µm) Informatica Depth (µm) Meccanica Sample 2 Diameter (µm) Depth (µm) EDM4-1 110 315 EDM5-1 120 97 Sample 2 Diameter (µm) Depth (µm) EDM6-1 150 13 3rd International Workshop on Laser Ultrasound for Metals
Prototype 3rd International Workshop on Laser Ultrasound for Metals
LU system perfomance LAB at DIID PROTOTYPE at TWI Sample 2 Diameter (µm) Depth (µm) EDM6-1 150 13
LU system perfomance Sample 05E7
Prototype evaluation End Start
Laser UT and Laser Thermography Inspection speed 2 mm/s Inspection speed 10 mm/s
LU experimental results Sample 1 - face A defect 1 (ϕ=470 µm, d=1.3 mm) defect 2 (ϕ =420 µm, d=0.6 mm) Sample 1 - face B defect 3 (ϕ =640 µm, d=0.88 mm) defect 4 (ϕ =640 µm, d=0.9 mm)
SD [C ] SD [C ] Standard Deviation or Mean value Begin ofdefect Begin ofdefect LT experimental results Distance over scanline 0,8 (a) 0,78 0,76 0,74 Defect 2/1 Defect 1/1 (b) 1,5 1,4 1,3 1,2 Defect 3/1 Defect 4/1 0,72 1,1 0,7 1 0,68 0,9 0,66 0,8 0,64 0,7 0,62 0,6 Sample 1 - face A defect 1 (ϕ=470 µm, d=1.3 mm) defect 2 (ϕ =420 µm, d=0.6 mm) 0,6 5 15 25 35 45 Distance [mm] 0,5 5 15 25 35 45 Distance [mm] Sample 1 - face B defect 3 (ϕ =640 µm, d=0.88 mm) defect 4 (ϕ =640 µm, d=0.9 mm)
LU and LT experimental results v v Sample 2 face C defect 1 (ϕ = 490 µm, d=0 mm) defect 2 (ϕ = 360 µm, d=0.1 mm) defect 3 (ϕ = 200 µm, d=0.3 mm)
Experimental results Cerniglia D., Scafidi M., Pantano A., Rudlin, J., 2015. Inspection of additive-manufactured layered components Ultrasonics 62, 292-298. Defects detected using LU and LT techniques
Conclusion Benefits Radiation pattern of L wave favorable Wide detection bandwidth, high sensitivity, robustness with the laser receiver B-scan image analysis for accurate evaluation of defect Limitations Limited for a range of flaw size/depth combination Safety hazard with high-power laser High cost Signal-to-noise depends on light collected (rough surfaces)
References Cerniglia, D., Scafidi, M., Pantano, A., Rudlin, J.. Inspection of additive-manufactured layered components (2015) Ultrasonics, 62, pp. 292-298 J. Rudlin, D. Cerniglia, M. Scafidi, C. Schneider. Inspection of Laser Powder Deposited Layers. 11th European Conference on Non-Destructive Testing (ECNDT 2014) Santospirito, S.P., Łopatka, R., Cerniglia, D., Słyk, K., Luo, B., Panggabean, D., Rudlin, J.. Defect detection in laser powder deposition components by laser thermography and laser ultrasonic inspections (2013) Proceedings of SPIE - The International Society for Optical Engineering, 8611, art. no. 86111N Rudlin, J., Cerniglia, D., Scafidi, M.. Inspection of laser powder deposited layers, 52nd Annual Conference of the British Institute of Non-Destructive Testing 2013, pp. 569-582 D. Cerniglia, M. Scafidi, A. Pantano, R. Łopatka. Laser Ultrasonic Technique for Laser Powder Deposition Inspection. 13th International Symposium on Nondestructive Characterization of Materials, 20-24 May 2013, Le Mans, France