Collaborative robotic wire + arc additive manufacture and sensor-enabled in-process ultrasonic non-destructive evaluation

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dc.contributor.authorZimermann, Rastislav
dc.contributor.authorMohseni, Ehsan
dc.contributor.authorVasilev, Momchil
dc.contributor.authorLoukas, Charalampos
dc.contributor.authorVithanage, Randika K. W.
dc.contributor.authorMacleod, Charles N.
dc.contributor.authorLines, David
dc.contributor.authorJavadi, Yashar
dc.contributor.authorEspirindio E Silva, Misael Pimentel
dc.contributor.authorFitzpatrick, Stephen
dc.contributor.authorHalavage, Steven
dc.contributor.authorMckegney, Scott
dc.contributor.authorPierce, Stephen Gareth
dc.contributor.authorWilliams, Stewart
dc.contributor.authorDingv, Jialuo
dc.date.accessioned2022-06-24T09:19:19Z
dc.date.available2022-06-24T09:19:19Z
dc.date.issued2022-05-31
dc.description.abstractThe demand for cost-efficient manufacturing of complex metal components has driven research for metal Additive Manufacturing (AM) such as Wire + Arc Additive Manufacturing (WAAM). WAAM enables automated, time- and material-efficient manufacturing of metal parts. To strengthen these benefits, the demand for robotically deployed in-process Non-Destructive Evaluation (NDE) has risen, aiming to replace current manually deployed inspection techniques after completion of the part. This work presents a synchronized multi-robot WAAM and NDE cell aiming to achieve (1) defect detection in-process, (2) enable possible in-process repair and (3) prevent costly scrappage or rework of completed defective builds. The deployment of the NDE during a deposition process is achieved through real-time position control of robots based on sensor input. A novel high-temperature capable, dry-coupled phased array ultrasound transducer (PAUT) roller-probe device is used for the NDE inspection. The dry-coupled sensor is tailored for coupling with an as-built high-temperature WAAM surface at an applied force and speed. The demonstration of the novel ultrasound in-process defect detection approach, presented in this paper, was performed on a titanium WAAM straight sample containing an intentionally embedded tungsten tube reflectors with an internal diameter of 1.0 mm. The ultrasound data were acquired after a pre-specified layer, in-process, employing the Full Matrix Capture (FMC) technique for subsequent post-processing using the adaptive Total Focusing Method (TFM) imaging algorithm assisted by a surface reconstruction algorithm based on the Synthetic Aperture Focusing Technique (SAFT). The presented results show a sufficient signal-to-noise ratio. Therefore, a potential for early defect detection is achieved, directly strengthening the benefits of the AM process by enabling a possible in-process repair.en_UK
dc.description.sponsorshipEngineering and Physical Sciences Research Council (EPSRC): EP/R027218/1, EP/R513349/1 and EP/P030165/1.en_UK
dc.identifier.citationZimermann R, Mohseni E, Vasilev M, et al., (2022) Collaborative robotic wire + arc additive manufacture and sensor-enabled in-process ultrasonic non-destructive evaluation, Sensors, Volume 22, Issue 11, May 2022, Article number 4203en_UK
dc.identifier.issn1424-8220
dc.identifier.urihttps://doi.org/10.3390/s22114203
dc.identifier.urihttps://dspace.lib.cranfield.ac.uk/handle/1826/18061
dc.language.isoenen_UK
dc.publisherMDPIen_UK
dc.rightsAttribution 4.0 International*
dc.rights.urihttp://creativecommons.org/licenses/by/4.0/*
dc.subjectnon-destructive evaluationen_UK
dc.subjectin-process robotic NDEen_UK
dc.subjectWire + Arc Additive Manufacture (WAAM)en_UK
dc.subjectultrasound testingen_UK
dc.subjecttotal focusing methoden_UK
dc.titleCollaborative robotic wire + arc additive manufacture and sensor-enabled in-process ultrasonic non-destructive evaluationen_UK
dc.typeArticleen_UK

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