Quality Control Using Ultrasonic Phased Array Inspection of Components Produced by Directed Energy Deposition in Ti6Al4V Alloy

Abstract

Additive manufacturing (AM) is rapidly becoming a viable manufacturing method for industrial metallic parts. This is related to the benefits achieved, such as reducing material wastage, an increase in design freedom and weight savings. But, to guarantee the highquality of the components produced, the non-destructive methods of inspection need to be optimised or developed. In this study, a Ti6Al4V 3D coupon was produced by the Laser Wire Directed Energy Deposition process (w-DED-LB), in which artificial holes of different diameters simulating defects were machined. To validate the quality control method after production by means of Ultrasonic Phased Array Techniques, the component was inspected using the Gekko equipment from Eddyfi Technologies, through the methodologies of the phased-array conventional mode and the Total Focusing Method (TFM). The probe used was a 5L64-64X7-NW1-P-5-OM, with a 5.0 MHz frequency system with 64 elements, with dimensions of length 64 mm, width 7 mm, and pitch of 1.0 mm. The results obtained showed that the TFM mode provides better detection of the defects, resolution, and measurement capabilities when compared with the conventional phased array mode.