Ultrasonic immersion testing enables nondestructive characterization of material microstructure through quantitative linkages between wave propagation parameters and features of interest. However, accurate measurements of metrics such as wave speed and attenuation generally require smooth test samples to ensure the reflected wave packets are not distorted. Thus, rough surfaces are mechanically polished before ultrasonic testing, which compromises the nondestructive nature of the measurement, distorting the sample geometry and imparting local damage. This challenge is particularly salient with the advent of manufacturing processes, such as metal additive manufacturing, that result in rough samples that must be characterized for heterogeneities in their as-manufactured state. This work examines the influence of surface roughness on longitudinal wave speed and attenuation in wrought and additively manufactured Ti-6Al-4V specimens. Samples are measured in an ultrasonic immersion setup before and after mechanical polishing using varying transducer frequencies and focal profiles. The resulting data informs the error generated in ultrasonic measurements as a function of roughness parameters, thereby informing the sample preparation needed for desired precision levels. Lastly, new measurement protocols are explored to correct for the presence of surface irregularities in a point-by-point fashion. This work was supported by the Robert W. Young Award for Undergraduate Student Research.
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