Journal
JOURNAL OF MANUFACTURING PROCESSES
Volume 80, Issue -, Pages 765-774Publisher
ELSEVIER SCI LTD
DOI: 10.1016/j.jmapro.2022.06.045
Keywords
Phased array ultrasound imaging; Wire plus arc additive manufacturing; In-process phased array inspection; Non-destructive testing of additive; manufacturing; Ultrasound phased array roller probe
Categories
Funding
- New Wire Additive Manufacturing project under EPSRC [EP/R027218/1]
- Robotic Wire + Arc Additive Manufacture project under EPSRC [EP/P031064/1]
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The wire + arc additive manufacturing (WAAM) process is effective for producing medium to large scale metal components. This paper presents the development and validation of a high temperature phased array ultrasound testing (PAUT) roller probe for in-process non-destructive testing (NDT) of WAAM components. The experimental results show that the PAUT roller probe can endure high temperatures and detect small defects.
The wire + arc additive manufacturing (WAAM) process, which combines an electric arc as a heat source and metal wire as feedstock is proving to be very effective when producing medium to large scale metal components. The non-destructive testing (NDT) of WAAM parts, while they are being produced, provides early intervention opportunities to rectify manufacturing nonconformities and to perform in-process quality assurance of the parts. This attracts a significant amount of material, time and cost savings. Therefore, this paper presents the research, development and validation of a high temperature phased array ultrasound testing (PAUT) roller probe to perform robotically delivered in-process NDT of WAAM components. The experimental results confirm that the PAUT roller probe can endure surface temperatures up to 350 ?, can be autonomously deployed via a robotic arm and can detect 1 mm diameter flat-bottom holes located 6 mm, 9 mm and 12 mm deep under the unmachined surface of a Ti-6Al-4V WAAM calibration block.
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