Session: 02-02-02: Session #2: Measurement Science, Sensors, Non-destructive Evaluation (NDE) and Process Control for Advanced Manufacturing

Paper Number: 96028

96028 - Development of the Ultrasonic System Integration With 3D Polymer Printing 

Non-destructive testing using ultrasonic sensors supplies manufacturers with methods of monitoring a parts integrity as it is being produced. The purpose of this experimentation is to demonstrate the usefulness and viability of using ultrasonic sensors to monitor the 3D printing process. In order to accomplish this, an attachment for the build plate of a 3D printer was developed that holds an ultrasonic sensor against the build plate while the printer is running initial tests. The ultrasonic sensor was used to analyze printing filaments and the build plate included with the printer. The results of ultrasonic investigation have demonstrated inefficiency of the composite plate in transduction of elastic waves and a steel build plate was suggested for further testing. Initial studies were conducted to explore material characteristics of the built plates and the printing materials. Ultrasonic setup with longitudinal and shear wave transducers were utilized to measure material properties such as Young’s modulus, shear modulus and the Poisson ratio. The time measured between voltage peaks of the ultrasonic sensor allowed for the measurement of the longitudinal and shear speeds in the material, which with known density permitted calculation of the elastic constants.  The ultrasonic testing revealed the longitudinal speed of sound through the new steel build plate to be 6900 m/s and 1150 m/s for the nylon print filament. It is anticipated that material characterization will also be conducted during the printing process.  This means heat will be introduced into the system and as a result the speed of sound through the build plate and filament will vary as a function of temperature. To better understand the role of temperature in real-time ultrasonic NDE, FEA model is developed to determine the transient temperature gradient through the steel build plate and filament during the printing process. Thermal imaging data is considered to assess the accuracy of the FEA model for the dynamic temperature distribution. The FEA model in conjunction with the thermal imaging and the real-time ultrasonic evaluation will be used to predict variation of sound speed in the build plate and filament. Once relationships between temperature variation and sound speed have been established properties such as Young's modulus can be calculated. It is anticipated that application of this approach will allow for assessment of material properties in near real time, which is critical for process monitoring and ensuring quality of the additively manufactured parts. Future work will be focused on exploring ultrasonic testing for damage detection in printed specimen. This will include utilization of the described methodology to identify prints that have defects such as cavities, non homogeneous sections and/or alien materials. 

Presenting Author: Maria D'orazio New Mexico Institute of Mining and Technology

Presenting Author Biography: Name: Maria D&#39;orazio<br/>Institution: New Mexico Institute of Mining and Technology

Authors:

Jonathan England New Mexico Institute of Mining and Technology
Ethan Darnell New Mexico Institute of Mining and Technology
Janak Bhakta New Mexico Institute of Mining and Technology
Maria D'orazio New Mexico Institute of Mining and Technology
Mariya Chukovenkova New Mexico Institute of Mining and Technology
Andrei Zagrai New Mexico Institute of Mining and Technology