World Industrial Reporter

Innovation Delivered Daily

  • Innovation
    • Innovation Article Archive
    • Innovative Companies
    • Innovation Strategies
    • New Equipment Innovations
  • New Products
  • Additive Manufacturing
  • Markets
    • Market Trends
    • Tradeshow Reports
    • White Papers
  • Logistics
  • Newsletters
World Industrial Reporter » Additive Manufacturing » LBU Speeds Up Defect Detection in Metal 3D Printing

LBU Speeds Up Defect Detection in Metal 3D Printing

May 2, 2022

ultrasound1 875x500px

Lawrence Livermore National Laboratory (LLNL) scientists have developed a laser-based ultrasound (LBU) technique to accurately capture defect-producing features in metal 3D printing.

According to the LLNL team, their all-optical ultrasound process utilizes surface acoustic waves (SAW) whose energy once scattered from voids, surface features, and melt lines—the tracks where the laser liquifies metal powder in Laser Powder Bed Fusion (LPBF) printing, helps pin point defects in metal 3D printing,

The engineers have validated their findings using optical microscopy and X-ray computed tomography (CT).

SAWs have been historically used to characterize surface and near-surface features such as cracks, pits and welds in engineering materials.

They are also used by geologists on a much larger length scale to detect subterranean features such as caves.

Going by this, one could as well say that SAWs are well-suited for characterizing melt lines in LPBF printing too.

To test SAWs’ potential in metal 3D printing, Stobbe and his team carried out experiments by producing laser melted lines using a fiber laser directed into a vacuum chamber and produced samples of titanium alloy for analysis with 100-watt, 150-watt and 350-watt powered lasers.

They next developed a method for producing and detecting surface acoustic waves, using a pulsed laser to generate ultrasound and measured the displacement with a photorefractive Iaser interferometer.

Stobbe’s team also performed simulations to inform the experimental measurements and assist with interpreting the results.

In order to do this, they simulated and measured the displacement from the pulsed laser and showed scattering from the melt line, as well as breaks in the melt line, metal splatter adjacent to the melt line and subsurface air voids under the melt line.

The scientists then measured these features experimentally and observed excellent agreement between simulation and experiment.

Results from the laser-based ultrasound (LBU) experiments were validated with optical microscopy for the surface features, and X-ray computed tomography for the sub-surface features.

According to LLNL engineer and lead author Kathryn Harke, the LBU system—in comparison with X-ray CT—offers better real-time inspection and can acquire and process data at a much faster rate.

Image and content: David Stobbe/LLNL

Share on

Filed Under: Additive Manufacturing, Innovation

The Pleasurable Crackliness of Chocolate
LM, Alginate Ink Promises Robust Smart Clothing
Avatar

About Aruna Urs

Aruna is an industrial journalist. He writes on innovations that emanate at the intersection of science and engineering having a profound impact on the manufacturing sector.

Follow me
Suppliers

Beckhoff at Hannover Messe: Shaping Digital Transformation with PC-Based Control

Beckhoff is renowned for offering an extensive range of innovations that are now considered standard throughout the automation world. At Hannover Messe 2022, Beckhoff will be demonstrating how their New Automation Technology actively supports digital transformation with high-performance control and automation solutions for optimizing machines, plants, and buildings, as well as in the field of e-mobility.
View Supplier Email this Supplier

Track & Trace in Production and Logistics

From incoming goods through production to warehouse and shipping - seamless identification with RFID provides decision-relevant information in real time. With the intelligent linking of RFID information from production and intralogistics with MES and ERP systems, you increase your efficiency and gain the necessary transparency for lean processes and digitized supply chains.
View Supplier Email this Supplier

Distance and Position Measurements Up to 10 kHz

The optoNCDT 1900 laser sensors with integrated high-performance controller offer a unique combination of speed, compact design and accuracy. The intelligent surface control enables extremely stable measurement results even on challenging surfaces with changing reflections. Easy installation also in confined spaces.

View Supplier Email this Supplier

High Accuracy, Non-Contact, Absolute Linear Sensor

Santest Model GY series are high accuracy, non-contact, absolute type linear sensors employing magnetostrictive, Wiedemann effect. An ultra-sonic wave generated by a moving magnet near a magnetostrictive wave-guide on which the sonic wave propagates to the head of the transducer.
View Supplier Email this Supplier

Affordable and Fixed Installed IR Cameras

Our thermal imaging cameras with multiple wavelength options, automatic spot finder function and autonomous operation are ideal for condition monitoring of machines and plants up to 5432 °F.
View Supplier Email this Supplier

Subscribe

Get the latest WIR reports straight to your inbox.

Free Newsletter Subscription

Find us on the social web.

  • About Us
  • Contact Us
  • Advertise
  • Terms Of Use
  • Privacy Policy
FREE NEWSLETTER SUBSCRIPTION

Get the latest WIR reports straight to your inbox.

  • Innovation Article Archive
  • Innovation Strategies
  • Innovative Companies
  • New Products
  • Additive Manufacturing
  • Market Trends
  • Tradeshow Reports
  • White Papers
  • Logistics
  • Newsletters
  • Fun Stuff
  • Industry Links
Follow us

© 2022 Thomas Publishing Company. All rights reserved.

Posting....