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

被引：11

作者：

Zimermann, Rastislav ^{[1
]}

Mohseni, Ehsan ^{[1
]}

Vasilev, Momchil ^{[1
]}

Loukas, Charalampos ^{[1
]}

Vithanage, Randika K. W. ^{[1
]}

Macleod, Charles N. ^{[1
]}

Lines, David ^{[1
]}

Javadi, Yashar ^{[1
]}

Espirindio E Silva, Misael Pimentel ^{[2
]}

Fitzpatrick, Stephen ^{[2
]}

Halavage, Steven ^{[2
]}

Mckegney, Scott ^{[2
]}

Pierce, Stephen Gareth ^{[3
]}

Williams, Stewart ^{[3
]}

Ding, Jialuo ^{[3
]}

机构：

[1] Univ Strathclyde, Ctr Ultrason Engn, Glasgow G1 1XW, Lanark, Scotland

[2] Univ Strathclyde, Adv Forming Res Ctr, Glasgow PA4 9LJ, Renfrew, Scotland

[3] Cranfield Univ, Welding Engn & Laser Proc Ctr, Cranfield MK43 0AL, Beds, England

来源：

SENSORS | 2022年 / 22卷 / 11期

基金：

英国工程与自然科学研究理事会;

关键词：

non-destructive evaluation; in-process robotic NDE; Wire plus Arc Additive Manufacture (WAAM); ultrasound testing; total focusing method; RESIDUAL-STRESS; MICROSTRUCTURE; STRATEGIES; DEFECTS; PARTS;

D O I：

10.3390/s22114203

中图分类号：

O65 [分析化学];

学科分类号：

070302 ; 081704 ;

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.

引用

页数：14