Adaptive non-destructive testing in additive manufacturing
| Reference number | |
| Coordinator | GKN AEROSPACE SWEDEN AB - Avd 9634PH |
| Funding from Vinnova | SEK 5 468 557 |
| Project duration | November 2017 - December 2020 |
| Status | Completed |
| Venture | National Aeronautical Research Program 7 |
| Call | 2017-02942-en |
Purpose and goal
The goal of this project has been to develop theoretical understanding through mathematical modelling and experimental work of ultrasonic inspections for aerospace parts produced with additive manufacturing. The project has stretched the procedures for ultrasonic inspection from the conventional to a state of the art approach using phased array probes. The phased array probe model was validated with good accuracy and used for optimization of inspection procedures. The project has led to scientific publications and new related research projects between industry and academia.
Expected results and effects
The project has helped to understand how ultrasound inspection with phased array technology should be applied to AM materials for aircraft engine components. The results point to both opportunities to achieve more efficient inspection procedures and to opportunities to use the technology for increased ability to detect and characterize material defects. These two factors are important for quality assurance of AM in the aviation industry and the method studied in the project is an important complement in future inspection processes for AM.
Planned approach and implementation
In the project, Chalmers has developed mathematical models and built up an environment for experimental tests where the ultrasound inspection with phased array could be studied. GKN has manufactured and analysed objects for studies and understanding of the inspection process, such as calibration with reference defects. This approach with three pillars (theoretical understanding, experiment and analysis) has been fundamental in an area that closely links to how the process for additive manufacturing is shaped both in terms of design, process and manufacturing outcomes.