Acoustic resonance testing of additive manufactured lattice structures

Additive manufacturing (AM) allows engineers to design and manufacture complex weight saving lattice structures with relative ease. These structures, however, present a challenge for inspection. A non-destructive testing and evaluation method used to assess material properties and quality is the focus of this paper, namely acoustic resonance (AR) testing. For this research, AR testing was conducted on weight saving lattice structures (fine and coarse) manufactured by powder bed fusion. The suitability of AR testing was assessed through a combined approach of experimental testing and FE modelling. A sensitivity study was conducted on the FE model to quantify the influence of element coarseness on the resonant frequency prediction and this needs to be taken into account in the application and analysis of the technique. The analysis was extended to extract effective modulus values for the lattice structures and the solid materials from every detected overtone, allowing for multiple measurements from a single AR test without the need to carefully isolate the fundamental. The AR and FE modelling modulus of elasticity values were validated using specimens of known properties. There was fair agreement between the FE and compression test extracted values of effective modulus for the coarse lattice. For the fine lattice, there was agreement in the values of effective modulus extracted from AR, 3-point bend, and compression experimental tests carried out. It was found that loose powder fusing from AM resulted in the fine lattice structure having a higher density (at least 1.5 times greater) than calculated due to the effect of loose powder adhesion. This effect resulted in an increased stiffness of the fine lattice structure. AR can be used as a measure of determining loose powder adhesion and other unique structural characteristics resulting from AM.