Ultrasonic phased array inspection of a Wire + Arc Additive Manufactured (WAAM) sample with intentionally embedded defects
Javadi, Yashar and MacLeod, Charles N. and Pierce, Stephen G. and Gachagan, Anthony and Lines, David and Mineo, Carmelo and Ding, Jialuo and Williams, Stewart and Vasilev, Momchil and Mohseni, Ehsan and Su, Riliang (2019) Ultrasonic phased array inspection of a Wire + Arc Additive Manufactured (WAAM) sample with intentionally embedded defects. Additive Manufacturing, 29. 100806. ISSN 2214-8604 (https://doi.org/10.1016/j.addma.2019.100806)
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Abstract
In this study, Wire + Arc Additive Manufacture (WAAM) was employed to manufacture a steel specimen with intentionally embedded defects which were subsequently used for calibration of an ultrasonic phased array system and defect sizing. An ABB robot was combined with the Cold Metal Transfer (CMT) Gas Metal Arc (GMA) process to deposit 20 layers of mild steel. Tungsten-carbide balls (ø1-3 mm) were intentionally embedded inside the additive structure after the 4th, 8th, 12th and 18th layers to serve as ultrasonic reflectors, simulating defects within the WAAM sample. An ultrasonic phased array system, consisting of a 5 MHz 64 Element phased array transducer, was used to inspect the WAAM sample non-destructively. The majority of the reflectors were detected successfully using Total Focusing Method (TFM), proving that the tungsten carbide balls were successfully embedded during the WAAM process and also that these are good ultrasonic reflectors. Owing to a lack of standards and codes for the ultrasonic inspection of WAAM samples (A. Lopez, R. Bacelar, et al., 2018), a calibration method and step-by-step inspection strategy were introduced and then used to estimate the size and shape of an unknown lack of fusion (LoF) indication. This was then validated by destructive analysis, showing a good correlation with the phased array results.
ORCID iDs
Javadi, Yashar ORCID: https://orcid.org/0000-0001-6003-7751, MacLeod, Charles N. ORCID: https://orcid.org/0000-0003-4364-9769, Pierce, Stephen G. ORCID: https://orcid.org/0000-0003-0312-8766, Gachagan, Anthony ORCID: https://orcid.org/0000-0002-9728-4120, Lines, David ORCID: https://orcid.org/0000-0001-8538-2914, Mineo, Carmelo ORCID: https://orcid.org/0000-0002-5086-366X, Ding, Jialuo, Williams, Stewart, Vasilev, Momchil, Mohseni, Ehsan ORCID: https://orcid.org/0000-0002-0819-6592 and Su, Riliang;-
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Item type: Article ID code: 69015 Dates: DateEvent31 October 2019Published29 July 2019Published Online22 July 2019AcceptedSubjects: Technology > Electrical engineering. Electronics Nuclear engineering Department: Faculty of Engineering > Electronic and Electrical Engineering
Strategic Research Themes > Advanced Manufacturing and MaterialsDepositing user: Pure Administrator Date deposited: 24 Jul 2019 13:53 Last modified: 26 Sep 2024 00:45 Related URLs: URI: https://strathprints.strath.ac.uk/id/eprint/69015