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Additively manufactured integrated slit mask for laser ultrasonic guided wave inspection

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Abstract

Guided ultrasonic waves are attractive for inspection of additively manufactured plate-like components. Illumination of a slit mask by a pulsed laser is one method by which guided ultrasonic waves can be generated. This work proposes a method for generating narrowband ultrasonic guided waves using an additively manufactured slit mask that is integrated onto the component during selective laser melting (SLM) process. Multiple guided wave modes with a dominant wavelength but with different frequencies were generated using the slit mask fabricated using AlSi12 material. The generated modes were identified using the time frequency response of the received signals and dispersion plots. Identifying the modes and its characteristics (frequency, wavelength, phase and group velocity) beforehand facilitates material and defect characterization. A multiphysics numerical model was developed to simulate laser generation of ultrasound and the model was validated using experimental results. The numerical model developed aided in understanding the physics of line arrayed laser ultrasonic generation and was used as a tool to optimize laser parameters. The developed model was used to study the effect of pulse width of the laser on Lamb wave mode generation. It was observed that a pulse width of 100 ns reduced the overall ultrasonic bandwidth to 4.5 MHz thereby limiting the modes to the fundamental modes A0 and S0 for the given wavelength of 0.8 mm. Rayleigh wave studies using a slit mask showed that the rate of decay of the fundamental frequency component was steeper than the rate of decay of the second harmonic component.

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Acknowledgements

The authors wish to thank Dr Rizwan Abdul Rahman Rashid and Mr Girish Thipperudrappa from Swinburne University of Technology (SUT), Melbourne, Australia, for their help and support for the fabrication of samples. The lead author of this paper is a joint-PhD student with SUT, Australia, through an IITM-SUT MoU. This research project team also acknowledge DMTC Limited (Australia). The paper has been written in line with the intellectual property rights granted to research partners from the original DMTC project.

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Authors and Affiliations

  1. Centre for Non-Destructive Evaluation, Department of Mechanical Engineering, Indian Institute of Technology Madras, Chennai, TN, 600036, India

    Geo Davis, Krishnan Balasubramaniam & Prabhu Rajagopal

  2. Faculty of Science, Engineering and Technology, Swinburne University of Technology, Melbourne, Victoria, 3122, Australia

    Geo Davis, Suresh Palanisamy & Romesh Nagarajah

  3. DMTC Limited, Hawthorn, Victoria, 3122, Australia

    Suresh Palanisamy

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  1. Geo Davis
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Correspondence to Suresh Palanisamy.

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Davis, G., Balasubramaniam, K., Palanisamy, S. et al. Additively manufactured integrated slit mask for laser ultrasonic guided wave inspection. Int J Adv Manuf Technol 110, 1203–1217 (2020). https://doi.org/10.1007/s00170-020-05946-y

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