Collaborative Robotic Wire + Arc Additive Manufacture and Sensor-Enabled In-Process Ultrasonic Non-Destructive Evaluation

Sensors

Misael Pimentel Espirindio E Silva¹  Scott Mckegney¹  Steven Halavage¹  Stephen Fitzpatrick¹  Yashar Javadi²  Charalampos Loukas²  Rastislav Zimermann²  Randika K. W. Vithanage²  Charles N. Macleod²  David Lines²  Momchil Vasilev²  Ehsan Mohseni²  Stewart Williams³  Stephen Gareth Pierce³  Jialuo Ding³ 

[1] Advanced Forming Research Centre, University of Strathclyde, Renfrew PA4 9LJ, UK;Centre for Ultrasonic Engineering, University of Strathclyde, Glasgow G1 1XW, UK;Welding Engineering and Laser Processing Centre, University of Cranfield, Cranfield MK43 0AL, UK;

关键词: non-destructive evaluation;    in-process robotic NDE;    Wire + Arc Additive Manufacture (WAAM);    ultrasound testing;    total focusing method;   

DOI  :  10.3390/s22114203

来源: DOAJ

【 摘 要 】

The 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.

【 授权许可】

Unknown