Dry-coupled ultrasound phased array inspection of as-built complex geometry metal additive manufactured components

Zimermann, Rastislav and Rizwan, Mohammad Khalid and Loukas, Charalampos and Vasilev, Momchil and Mohseni, Ehsan and Vithanage, Randika K.W. and MacLeod, Charles N. and Lines, David and Pimentel, Misael and Fitzpatrick, Stephen and Halavage, Steven and McKegney, Scott and Pierce, Gareth and Williams, Stewart and Ding, Jialuo (2023) Dry-coupled ultrasound phased array inspection of as-built complex geometry metal additive manufactured components. In: 31st ASNT Research symposium, 2023-06-20 - 2023-06-23, Greater Columbus Convention Centre.

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Abstract

Growing demand for smart and flexible factories, producing high-value components cost-effectively has driven the development of large-scale metal Additive Manufacturing (AM) processes such as Wire+Arc Additive Manufacturing (WAAM). To match the strengths of metal AM, a novel high-temperature dry-coupled ultrasound roller-probe was developed to facilitate quality assurance, deployed in-process. In this work, the authors present novel work and research from the field of an automated dry-coupled ultrasound in-process NDE. During the experiments, a titanium complex-shaped WAAM, featuring characteristic geometries and a range of flat bottom holes in critical locations drives the development of an NDE strategy deployable on real as-built WAAM geometries. The outcome of this work demonstrates a novel knowledge applicable to path planning strategy for the best ultrasound wave propagation into critical locations within a specimen along with further enhancements applied to the existing robotic NDE system.

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