Resonant Ultrasonic Testing can Quantitatively Assess the Microscopic Porosity of Complex-Shaped Additively Manufactured AlSi10Mg Components

IF 2.6 3区材料科学 Q2 MATERIALS SCIENCE, CHARACTERIZATION & TESTING

Journal of Nondestructive Evaluation Pub Date : 2024-04-06 DOI:10.1007/s10921-024-01064-x

Michail Skiadopoulos, Dominic J. Prato, Evan P. Bozek, Corey J. Dickman, Edward W. Reutzel, David J. Corbin, Parisa Shokouhi

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Abstract

The utility of resonant ultrasonic testing for quality control of complex-shaped additively manufactured (AM) components in terms of porosity variations is investigated. A fully non-contact test setup is used to investigate differences in the volumetric porosity between AM AlSi10Mg samples. A set of 96 samples with programmatically induced pores varying in nominal total porosity between 0% and 2% is tested: one half of the samples are prismatic, and the other half have a complex internal Triply Periodic Minimal Surface (TPMS) structure. In addition, a subset of the samples is scanned using X-ray micro-computed tomography (µ-CT). It is found that the resonance frequency corresponding to the 1st compressional mode can predict the total nominal porosity even in TPMS samples. From statistical analysis, the smallest detectable porosity difference is found to be 0.25% for the prismatic samples and 0.5% for the TPMS samples. The experimental results agree well with the predictions of finite element (FE) simulations and analytical models. However, X-ray µ-CT appears to underestimate the porosity, possibly due to its inability to resolve the small pores. Our findings suggest that resonant ultrasonic testing can quantitatively assess the total porosity of AM parts having complex geometries.

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共振超声波测试可定量评估复杂形状铝硅镁叠加制造部件的微观孔隙率

本文研究了共振超声波测试在复杂形状的快速成型（AM）部件的孔隙率变化质量控制方面的实用性。采用完全非接触式测试装置来研究 AM AlSi10Mg 样品之间体积孔隙率的差异。测试了一组 96 个样品，这些样品的标称总孔隙率在 0% 到 2% 之间，其中一半为棱柱形，另一半具有复杂的内部三周期最小表面 (TPMS) 结构。此外，还使用 X 射线微型计算机断层扫描（µ-CT）技术对部分样品进行了扫描。结果发现，即使在 TPMS 样品中，与第一压缩模式相对应的共振频率也能预测总标称孔隙率。通过统计分析发现，棱柱样品和 TPMS 样品可检测到的最小孔隙率差异分别为 0.25%和 0.5%。实验结果与有限元（FE）模拟和分析模型的预测结果十分吻合。不过，X 射线 µ-CT 似乎低估了孔隙率，这可能是由于它无法分辨小孔隙。我们的研究结果表明，共振超声波测试可以定量评估具有复杂几何形状的 AM 零件的总孔隙率。

本文章由计算机程序翻译，如有差异，请以英文原文为准。

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来源期刊

Journal of Nondestructive Evaluation 工程技术-材料科学：表征与测试

CiteScore

4.90

自引率

7.10%

发文量

审稿时长

9 months

期刊介绍： Journal of Nondestructive Evaluation provides a forum for the broad range of scientific and engineering activities involved in developing a quantitative nondestructive evaluation (NDE) capability. This interdisciplinary journal publishes papers on the development of new equipment, analyses, and approaches to nondestructive measurements.