Non-contact assessment of porosity in metal 3D printed parts by vibration spectra

Volumetric porosity as a common defect in metal 3D printing (3DP) that can significantly impede the mechanical properties of products. Traditional methods of porosity control (microscopy) and non-destructive testing (computed tomography) usually are not applicable at the production site. In this study, sensitivity of three examined testing modalities based on acoustic methods and vibration analysis to changes in the volumetric porosity of 3DP parts was examined. Test objects were cylindrical specimens made of AlMg powder by 3DP with a gradually dosed porosity from 0.5 to 4.0%. Ultrasonic testing by through transmission showed the best accuracy using ultrasound velocity and pulse intensity parameters. Shifts of resonant frequency and spectral density and appearance of side harmonics were the manifestations of increased porosity using vibration approaches. The method comprising a loudspeaker as a vibration exciter and an optoelectronic device for remote sensing of vibration is the most attractive from the point of view of application to objects of complex geometry.