Additively manufactured (AM) components often exhibit significant discontinuities and indications without a clear understanding of how they might affect the mechanical properties of a part during qualification and service. This uncertainty is unacceptable for the design and manufacturing of most aerospace components. Current research in both mechanical testing and nondestructive evaluation involves developing methods for characterizing and inspecting AM components as the use of such materials continues to rise. Although several AM manufacturing methods have been developed in recent decades, this paper focuses on AM production-ready processes for a direct metal laser sintering (DMLS) powder bed fusion machine and will provide background on Sandia National Laboratories' research efforts in this area. Tensile bar samples manufactured using the DMLS powder bed fusion method were inspected in this study, and the results of ultrasonic spectroscopy for assessing internal flaws will be presented. A combination of material property evaluation, microstructural characterization, and nondestructive inspection techniques will also be described. The results obtained from these material evaluation methods assist in determining inspection limits and methods for qualifying AM materials.
Ultrasound techniques are capable of monitoring changes in the time-of-flight as a material is exposed to different thermal environments. The focus of the present study is to identify the phase of a material via ultrasound compression wave measurements in a through transmission experimental setup as the material is heated from a solid to a liquid and then allowed to re-solidify. The present work seeks to expand upon the authors' previous research, which proved this through transmission phase monitoring technique was possible, by considering different experimental geometries. The relationship between geometry, the measured speed of sound, and the temperature profile is presented. The use of different volumes helps in establishing a baseline understanding of which aspects of the experiment are geometry dependent and which are independent. The present study also investigates the relationship between the heating rate observed in the experiment and the measured speed of sound. The trends identified between the experimental geometry, heat rate and ultrasound wave speed measurement assist in providing a baseline understanding of the applicability of this technique to various industries, including the polymer industry and the oil industry.
Ultrasonic analysis is being explored as a way to capture events during melting of highly dispersive wax. Typical events include temperature changes in the material, phase transition of the material, surface flows and reformations, and void filling as the material melts. Melt tests are performed with wax to evaluate the usefulness of different signal processing algorithms in capturing event data. Several algorithm paths are being pursued. The first looks at changes in the velocity of the signal through the material. This is only appropriate when the changes from one ultrasonic signal to the next can be represented by a linear relationship, which is not always the case. The second tracks changes in the frequency content of the signal. The third algorithm tracks changes in the temporal moments of a signal over a full test. This method does not require that the changes in the signal be represented by a linear relationship, but attaching changes in the temporal moments to physical events can be difficult. This paper describes the algorithm paths applied to experimental data from ultrasonic signals as wax melts and explores different ways to display the results.