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Non-Destructive Testing Using Eddy Current Sensors for Defect Detection in Additively Manufactured Titanium and

Heba E Farag1, Ehsan Toyserkani1, Mir Behrad Khamesee1

  • 1Department of Mechanical and Mechatronics Engineering, University of Waterloo, Waterloo, ON N2L 3G1, Canada.

Sensors (Basel, Switzerland)
|July 27, 2022
PubMed
Summary
This summary is machine-generated.

Eddy-current probes effectively detect subsurface defects in additively manufactured stainless-steel and titanium parts. A simple paper coating enhances signal quality, improving defect detection capabilities for quality control.

Keywords:
absolute probeadditive manufacturingdefectseddy currentmagnetic coilmagnetic sensorsnon-destructive testingsensor designs

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Area of Science:

  • Materials Science
  • Non-Destructive Testing
  • Additive Manufacturing

Background:

  • Laser Additive Manufacturing (LAM) produces complex metal parts but can introduce subsurface defects.
  • Effective detection of these defects is crucial for ensuring part integrity and performance.
  • Eddy-current testing is a non-destructive method suitable for detecting surface and near-surface flaws.

Purpose of the Study:

  • To evaluate the efficacy of different eddy-current probe designs for detecting artificial subsurface defects in LAM-produced stainless-steel and titanium.
  • To investigate methods for improving signal quality and defect detection sensitivity.
  • To determine the suitability of specific probe types for different defect morphologies.

Main Methods:

  • Utilized absolute and commercial reflection eddy-current probes to inspect stainless-steel (316) and titanium (TI-64) samples fabricated via LAM.
  • Introduced artificial defects of varying sizes and depths, including notches and blind holes.
  • Assessed the impact of a thin paper coating on probe performance and signal-to-noise ratio.

Main Results:

  • Both probe types successfully detected subsurface defects in both materials, with signal values ranging from 20-200 millivolts.
  • A paper coating on the probes significantly reduced the effect of surface roughness and smoothed detected signals.
  • The smallest detected defect was a 0.07 mm wide notch; blind holes with radii of 0.17-0.3 mm were also detected.
  • Absolute probes were better for cracks/incomplete fusion, while reflection probes excelled at small blind holes.

Conclusions:

  • Eddy-current testing is a viable method for subsurface defect detection in additively manufactured metals.
  • Probe design and minor modifications (e.g., paper coating) can optimize defect detection.
  • This technique holds potential for in-situ quality control during the additive manufacturing process after melt pool solidification.