Increasing the speed of automated ultrasonic inspection of as-built additive manufacturing components by the adoption of virtual source aperture

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dc.contributor.authorZimermann, Rastislav
dc.contributor.authorMohseni, Ehsan
dc.contributor.authorVithanage, Randika K. W.
dc.contributor.authorLines, David
dc.contributor.authorFoster, Euan
dc.contributor.authorMacleod, Charles N.
dc.contributor.authorPierce, Stephen Gareth
dc.contributor.authorMarinelli, Gianrocco
dc.contributor.authorWilliams, Stewart
dc.contributor.authorDing, Jialuo
dc.date.accessioned2022-06-24T09:47:51Z
dc.date.available2022-06-24T09:47:51Z
dc.date.issued2022-06-15
dc.description.abstractWire + Arc Additive Manufacture (WAAM) is an economical manufacturing technique to build components. To maintain the commercial and technical benefits, inspection is desired at each layer of the build. New conformable phased array roller-probes offer the potential to inspect the as-built sample in-process or on completion. A challenge with such inspections is the refraction of the ultrasonic waves at multiple interfaces. The Synthetic Aperture Focusing Technique (SAFT) and Total Focusing Method (TFM), combined with Full Matrix Capture (FMC) acquisition enabled imaging through the as-built WAAM surface. However, single-element firings, associated with FMC are a limiting factor due to the lower energy at transmission, while the high number of firings and subsequent larger data size negatively affect inspection speed. This work introduces the concept of Virtual Source Aperture (VSA) for ultrasonic roller-probe inspection, through modelling of VSA on custom-designed calibration WAAM block. The concept is then demonstrated on a mock as-built WAAM sample inspection with reference defects. The results demonstrate that a markedly lower number of transmissions are required to match the performance of the FMC counterpart while increasing the energy levels. Moreover, an almost 50% reduction in the data size enabled a doubling of the inspection speed.en_UK
dc.identifier.citationZimermann R, Mohseni E, Vithanage RKW, et al., (2022) Increasing the speed of automated ultrasonic inspection of as-built additive manufacturing components by the adoption of virtual source aperture. Materials and Design, Volume 220, August 2022, Article number 110822en_UK
dc.identifier.issn0264-1275
dc.identifier.urihttps://doi.org/10.1016/j.matdes.2022.110822
dc.identifier.urihttps://dspace.lib.cranfield.ac.uk/handle/1826/18062
dc.language.isoenen_UK
dc.publisherElsevieren_UK
dc.rightsAttribution-NonCommercial-NoDerivatives 4.0 International*
dc.rights.urihttp://creativecommons.org/licenses/by-nc-nd/4.0/*
dc.subjectWire+Arc Additive Manufacturing (WAAM)en_UK
dc.subjectPhased Array Ultrasound Testing (PAUT)en_UK
dc.subjectTotal Focusing Technique (TFM)en_UK
dc.subjectSynthetic Aperture Focusing Technique (SAFT)en_UK
dc.subjectVirtual Source Aperture (VSA)en_UK
dc.titleIncreasing the speed of automated ultrasonic inspection of as-built additive manufacturing components by the adoption of virtual source apertureen_UK
dc.typeArticleen_UK

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