Non-Contact Ultrasonic Detection for Additive Manufacturing Defects
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Solution Overview
Problem
Current nondestructive testing means in additive manufacturing cannot implement real-time online testing, leading to inefficiencies and potential waste in identifying structural defects.
Innovation Solution
A method and system utilizing a non-contact sensor to measure ultrasonic waves generated during additive manufacturing, forming a visual ultrasonic field, and applying windowed filtering and continuous wavelet transforms to detect defects in real time by analyzing the slope change of the incident wave curve.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If non-contact sensors are used to measure ultrasonic waves during additive manufacturing, then real-time online defect detection is enabled, but device complexity increases
Solution Approach 1:
The pulse laser serves dual functions: it acts as both the machining tool for additive manufacturing and the excitation source for ultrasonic wave generation. This multi-functionality eliminates the need for separate testing equipment, enabling real-time defect detection without increasing overall device complexity.
Solution Approach 2:
The testing system is integrated into the additive manufacturing process by combining the laser machining system with ultrasonic sensing. The non-contact sensor is positioned to monitor ultrasonic waves generated during manufacturing, merging production and inspection operations into a unified system.
2Productivity
If testing is performed after machining is completed, then measurement precision is maintained, but productivity decreases due to inability to remove defective products early
Solution Approach 1:
The system performs defect detection during the additive manufacturing process itself, before the entire part is completed. By monitoring ultrasonic waves in real-time during layer-by-layer construction, defects are identified at the earliest possible stage, allowing immediate process adjustment or part removal without completing unnecessary manufacturing steps.
Solution Approach 2:
The ultrasonic monitoring operates continuously throughout the additive manufacturing process, providing uninterrupted real-time feedback on structural integrity. This continuous detection enables immediate identification of defects without interrupting the manufacturing flow, maximizing productivity while maintaining quality control.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Enables real-time online detection of structural defects, reducing waste and improving product quality by identifying and removing defective products during the manufacturing process.
Implementation Method 1
an ultrasonic wave generated during additive manufacturing is measured in real time by using a non-contact sensor
Implementation Method 2
a pulse laser with a high energy density is used for machining and molding
Data Source
AI summary
The present disclosure relates to a method and system for detecting a structural defect in additive manufacturing. The method includes: layering a three-dimensional model of an additive manufacturing test piece to obtain a two-dimensional contour of an interface of each layer, and generating a machining path; arranging a non-contact sensor at a fixed measuring point of the additive manufacturing test piece, and acquiring an ultrasonic signal at each machining point when a pulse laser conducts machining point by point along the machining path; forming a visual ultrasonic field based on all the ultrasonic signals, and determining ultrasonic field data; determining, based on the ultrasonic field data, a curve of a peak of an incident wave changing with the machining path; and determining whether a machining defect exists at the machining points based on the curve of the peak of the incident wave changing with the machining path.