Surface roughness induced attenuation of ultrasonic waves transmitted through a liquid‐solid interface at oblique incidence

1991 ◽  
Vol 89 (4B) ◽  
pp. 1971-1972
Author(s):  
Peter B. Nagy
Keyword(s):  
Surface Roughness ◽  
Oblique Incidence ◽  
Ultrasonic Waves ◽  
Solid Interface

Estimation of Internal Surface Roughness of Additively Manufactured Components Under Complex Conditions Using Artificial Intelligence and Measurements of Ultrasonic Backscatter

2021 ◽  
Author(s):  
Mohamed Subair Syed Akbar Ali ◽  
Mato Pavlovic ◽  
Prabhu Rajagopal
Keyword(s):  
Artificial Intelligence ◽  
Surface Roughness ◽  
Internal Surface ◽  
Side Surface ◽  
Ultrasonic Waves ◽  
Model Parameters ◽  
Ultrasonic Measurements ◽  
Neural Network Algorithm ◽  
X Ray Computed ◽  
Pulse Echo

Abstract Additive Manufacturing (AM) is increasingly being considered for fabrication of components with complex geometries in various industries such as aerospace and healthcare. Control of surface roughness of components is thus a crucial aspect for more widespread adoption of AM techniques. However, estimating the internal (or ‘far-side’) surface roughness of components is a challenge, and often requires sophisticated techniques such as X-ray computed tomography, which are difficult to implement online. Although ultrasound could potentially offer a solution, grain noise and inspection surface conditions complicate the process. This paper studies the feasibility of using Artificial Intelligence (AI) in conjunction with ultrasonic measurements for rapid estimation of internal surface roughness in AM components, using numerical simulations. In the first models reported here, a pulse-echo configuration is assumed, whereby a specimen sample with rough surfaces is insonified with bulk ultrasonic waves and the backscatter is used to generate A-scans. Simulations are carried out for various combinations of the model parameters, yielding a large number of such A-scans. A neural network algorithm is then created and trained on a subset of the datasets so generated using simulations, and later used to predict the roughness from the rest. The results demonstrate the immense potential of this approach in inspection automation for rapid roughness assessments in AM components, based on ultrasonic measurements.

scholarly journals Effect of surface roughness on ultrasonic inspection of electron beam melting ti‐6AL‐4V

2019 ◽  
Vol 3 (2) ◽  
pp. 131-141
Author(s):  
Evan Hanks ◽  
Anthony Palazotto ◽  
David Liu
Keyword(s):  
Surface Roughness ◽  
Electron Beam ◽  
New Technology ◽  
High Surface ◽  
Ultrasonic Inspection ◽  
Ultrasonic Waves ◽  
Aviation Industry ◽  
Sound Waves ◽  
Machined Surface ◽  
Content Type

Purpose Experimental research was conducted on the effects of surface roughness on ultrasonic non-destructive testing of electron beam melted (EBM) additively manufactured Ti-6Al-4V. Additive manufacturing (AM) is a developing technology with many potential benefits, but certain challenges posed by its use require further research before AM parts are viable for widespread use in the aviation industry. Possible applications of this new technology include aircraft battle damage repair (ABDR), small batch manufacturing to fill supply gaps and replacement for obsolete parts. This paper aims to assess the effectiveness of ultrasonic inspection in detecting manufactured flaws in EBM-manufactured Ti-6Al-4V. Additively manufactured EBM products have a high surface roughness in “as-manufactured” condition which is an artifact of the manufacturing process. The surface roughness is known to affect the results of ultrasonic inspections. Experimental data from this research demonstrate the ability of ultrasonic inspections to identify imbedded flaws as small as 0.51 mm at frequencies of 2.25, 5 and 10 MHz through a machined surface. Detection of flaws in higher surface roughness samples was increased at a frequency of 10 MHz opposed to both lower frequencies tested. Design/methodology/approach The approach is to incorporate ultrasonic waves to identify flaws in an additive manufactured specimen Findings A wave frequency of 10 MHz gave good results in finding flaws even with surface roughness present. Originality/value To the best of the authors’ knowledge, this was the first attempt that was able to identify small flaws using ultrasonic sound waves in which surface roughness was present.

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