Measuring the Depth of Subsurface Defects in Additive Manufacturing Components by Laser-Generated Ultrasound

A novel 3D evaluation method for surface defects using broadband laser-generated Rayleigh waves with wavenumber analysis

To address the issues of large imaging errors for small defects and the difficulty in depth evaluation using local wavenumber estimation for surface defect imaging, a novel three-dimensional (3D) evaluation method for surface defects using broadband laser-generated Rayleigh waves with wavenumber analysis is proposed. A finite element model is established to investigate the interaction between the Rayleigh wave and the surface defect and reveal the wavenumber change mechanism of the non-dispersive Rayleigh wave in the case of defects. It is discovered that when the Rayleigh wave encounters the surface defect, various mode-converted scattered waves are generated, resulting in the appearance of new components with wavenumbers lower than that of the incident Rayleigh wave in the wavenumber domain. Additionally, the maximum amplitude of the Rayleigh wave in the B-scan image increases as the defect depth increases. Based on the simulation analysis, a 3D evaluation method for surface defects is proposed. Firstly, the scattered Rayleigh wave caused by the defect is extracted using frequency-wavenumber analysis. Secondly, a space-frequency-wavenumber analysis is used to determine the local wavenumber of the scattered Rayleigh wave for defect imaging. Finally, the defect depth is estimated by analyzing the maximum amplitude of the Rayleigh wave. A surface defect detection experiment is conducted to verify the effectiveness of the proposed method, and the experimental results demonstrate that the proposed method can suppress noise interference and accomplish high-precision imaging of small surface defects compared to the traditional method. Moreover, the method can establish a linear mapping relationship between the defect depth and the maximum amplitude of the Rayleigh wave for depth evaluation. The research results can provide a potential application for the 3D evaluation of surface defects.

Debonding Detection in Aluminum/Rigid Polyurethane Foam Composite Plates Using A0 Mode LAMB Wave EMATs

Aluminum/rigid polyurethane foam composite plates (ARCPs) are widely used for thermal insulation. The interface debonding generated during manufacturing degrades the thermal insulation performance of an ARCP. In this study, the debonding of an ARCP, a composite plate with a porous and damped layer of rigid polyurethane foam (RPUF), was detected using A₀ mode Lamb wave electromagnetic acoustic transducers (EMATs). The low energy transmission coefficient at the interface caused by the large acoustic impedance difference between aluminum and RPUF made the detection difficult. Based on these structural characteristics, an A₀ mode Lamb wave with large out-of-plane displacement was used to detect the debonding. EMATs are preferred for generating A₀ mode Lamb waves due to their advantages of being noncontact, not requiring a coupling agent, and providing convenient detection. A finite element simulation model considering the damping of the RPUF layer, the damping of the PU film at the interface, and the bonding stiffness of the interface was established. The simulation results indicated that the Lamb wave energy in the aluminum plate transmits into the RPUF layer in small amounts. However, the transmitted energy rapidly attenuated and was not reflected into the aluminum plate, as the RPUF layer was thick and highly damped. Therefore, energy attenuation was evident and could be used to characterize the debonding. An approximately linear relationship between the amplitude of the received signals and the debonding length was obtained. Experiments were performed on an ARCP using EMATs, and the experimental results were in good agreement with the simulation results.