In Situ Ultrasonic Testing for Wire Arc Additive Manufacturing Applications

Ana Beatriz Lopez; José Pedro Sousa; João P. M. Pragana; Ivo M. F. Bragança; Telmo G. Santos; Carlos M. A. Silva

doi:10.3390/machines10111069

In Situ Ultrasonic Testing for Wire Arc Additive Manufacturing Applications

Ana Beatriz Lopez, José Pedro Sousa, João P. M. Pragana, Ivo M. F. Bragança, Telmo G. Santos, Carlos M. A. Silva

Research output: Contribution to journal › Article › peer-review

5 Citations (Scopus)

70 Downloads (Pure)

Abstract

In this paper, we present a non-destructive testing (NDT) technique based on in situ detection of defects up to 100 °C by ultrasonic testing (UT) during construction of parts by a metal additive manufacturing technology known as wire arc additive manufacturing (WAAM). The proposed technique makes use of interlayer application of commercial solder flux to serve as coupling medium for in situ inspection using a special-purpose UT probe. The experimental work was carried out in deposited ER5356 aluminum straight walls following a threefold structure. First, characterization tests with geometrically similar walls with and without interlayer application of solder flux highlight its neutrality, with no effect on the chemical, metallurgical and mechanical properties of the walls. Secondly, UT tests on walls at temperatures ranging from room temperature to 100 °C demonstrate the satisfactory performance of the solder flux as a coupling medium, with little to no soundwave amplitude losses or noise. Finally, acoustic attenuation, impedance and transmission estimations highlight the effectiveness of the proposed technique, establishing a basis for the future development of automated NDT systems for in situ UT of additive manufacturing processes.

Original language	English
Article number	1069
Number of pages	16
Journal	Machines
Volume	10
Issue number	11
DOIs	https://doi.org/10.3390/machines10111069
Publication status	Published - 12 Nov 2022

Keywords

high-temperature inspection
non-destructive testing
ultrasonic testing
wire arc additive manufacturing

Access to Document

10.3390/machines10111069Licence: CC BY

In Situ Ultrasonic Testing for Wire Arc AdditiveFinal published version, 6.96 MBLicence: CC BY

Cite this

@article{817968c16a3c451599fb0365f3a155e8,

title = "In Situ Ultrasonic Testing for Wire Arc Additive Manufacturing Applications",

abstract = "In this paper, we present a non-destructive testing (NDT) technique based on in situ detection of defects up to 100 °C by ultrasonic testing (UT) during construction of parts by a metal additive manufacturing technology known as wire arc additive manufacturing (WAAM). The proposed technique makes use of interlayer application of commercial solder flux to serve as coupling medium for in situ inspection using a special-purpose UT probe. The experimental work was carried out in deposited ER5356 aluminum straight walls following a threefold structure. First, characterization tests with geometrically similar walls with and without interlayer application of solder flux highlight its neutrality, with no effect on the chemical, metallurgical and mechanical properties of the walls. Secondly, UT tests on walls at temperatures ranging from room temperature to 100 °C demonstrate the satisfactory performance of the solder flux as a coupling medium, with little to no soundwave amplitude losses or noise. Finally, acoustic attenuation, impedance and transmission estimations highlight the effectiveness of the proposed technique, establishing a basis for the future development of automated NDT systems for in situ UT of additive manufacturing processes.",

keywords = "high-temperature inspection, non-destructive testing, ultrasonic testing, wire arc additive manufacturing",

author = "Lopez, {Ana Beatriz} and Sousa, {Jos{\'e} Pedro} and Pragana, {Jo{\~a}o P. M.} and Bragan{\c c}a, {Ivo M. F.} and Santos, {Telmo G.} and Silva, {Carlos M. A.}",

note = "info:eu-repo/grantAgreement/FCT/6817 - DCRRNI ID/UIDB%2F50022%2F2020/PT# info:eu-repo/grantAgreement/FCT/6817 - DCRRNI ID/UIDB%2F00667%2F2020/PT# Publisher Copyright: {\textcopyright} 2022 by the authors.",

year = "2022",

month = nov,

day = "12",

doi = "10.3390/machines10111069",

language = "English",

volume = "10",

journal = "Machines",

issn = "2075-1702",

publisher = "MDPI - Multidisciplinary Digital Publishing Institute",

number = "11",

}

TY - JOUR

T1 - In Situ Ultrasonic Testing for Wire Arc Additive Manufacturing Applications

AU - Lopez, Ana Beatriz

AU - Sousa, José Pedro

AU - Pragana, João P. M.

AU - Bragança, Ivo M. F.

AU - Santos, Telmo G.

AU - Silva, Carlos M. A.

PY - 2022/11/12

Y1 - 2022/11/12

N2 - In this paper, we present a non-destructive testing (NDT) technique based on in situ detection of defects up to 100 °C by ultrasonic testing (UT) during construction of parts by a metal additive manufacturing technology known as wire arc additive manufacturing (WAAM). The proposed technique makes use of interlayer application of commercial solder flux to serve as coupling medium for in situ inspection using a special-purpose UT probe. The experimental work was carried out in deposited ER5356 aluminum straight walls following a threefold structure. First, characterization tests with geometrically similar walls with and without interlayer application of solder flux highlight its neutrality, with no effect on the chemical, metallurgical and mechanical properties of the walls. Secondly, UT tests on walls at temperatures ranging from room temperature to 100 °C demonstrate the satisfactory performance of the solder flux as a coupling medium, with little to no soundwave amplitude losses or noise. Finally, acoustic attenuation, impedance and transmission estimations highlight the effectiveness of the proposed technique, establishing a basis for the future development of automated NDT systems for in situ UT of additive manufacturing processes.

AB - In this paper, we present a non-destructive testing (NDT) technique based on in situ detection of defects up to 100 °C by ultrasonic testing (UT) during construction of parts by a metal additive manufacturing technology known as wire arc additive manufacturing (WAAM). The proposed technique makes use of interlayer application of commercial solder flux to serve as coupling medium for in situ inspection using a special-purpose UT probe. The experimental work was carried out in deposited ER5356 aluminum straight walls following a threefold structure. First, characterization tests with geometrically similar walls with and without interlayer application of solder flux highlight its neutrality, with no effect on the chemical, metallurgical and mechanical properties of the walls. Secondly, UT tests on walls at temperatures ranging from room temperature to 100 °C demonstrate the satisfactory performance of the solder flux as a coupling medium, with little to no soundwave amplitude losses or noise. Finally, acoustic attenuation, impedance and transmission estimations highlight the effectiveness of the proposed technique, establishing a basis for the future development of automated NDT systems for in situ UT of additive manufacturing processes.

KW - high-temperature inspection

KW - non-destructive testing

KW - ultrasonic testing

KW - wire arc additive manufacturing

UR - http://www.scopus.com/inward/record.url?scp=85149590066&partnerID=8YFLogxK

U2 - 10.3390/machines10111069

DO - 10.3390/machines10111069

M3 - Article

AN - SCOPUS:85149590066

SN - 2075-1702

VL - 10

JO - Machines

JF - Machines

IS - 11

M1 - 1069

ER -

In Situ Ultrasonic Testing for Wire Arc Additive Manufacturing Applications

Abstract

Keywords

Access to Document

Other files and links

Fingerprint

Cite this