Abstract
The demand for metal additive manufacturing (AM), also known as three-dimensional (3D) printing, is increasing owing to its ability to produce components with complex shapes, heterogeneous material properties, low material waste, etc. However, for broader acceptance of metal AM, quality assurance of mechanical properties, such as elastic (Young's) modulus, Poisson's ratio, and ductility, is becoming critical in additively manufactured components. This study proposes a non-contact, non-destructive and automated eddy-current technique for yield strength estimation of additively manufactured Ti–6Al–4V components with the potential for online operation during metal AM. After conducting the eddy-current measurement at a specific inspection point within the Ti–6Al–4V component, the relationship between the eddy-current phase value and electrical conductivity is established. Subsequently, the yield strength of the Ti–6Al–4V component is estimated by utilizing the analytical relationship between yield strength and electrical conductivity, which is based on Andrew's research and the Hall–Petch relationship. For experimental validation, Ti–6Al–4V test specimens with different electrical conductivities (yield strengths) were fabricated by adjusting the cooling rate during metal direct energy deposition AM. Then, the yield strengths estimated using the proposed technique were compared with those obtained using conventional destructive tensile tests. The results show that the proposed technique can estimate the yield strength with an error rate of less than 8%. The uniqueness of this study lies in (1) the theoretical derivation of the relationship between the eddy-current phase value and yield strength, (2) non-destructive, non-contact, and automated estimation of the yield strength using eddy-current measurements, and (3) performance evaluation using additively manufactured Ti–6Al–4V specimens with different yield strengths.
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