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Towards Enhanced Eddy Current Testing Array Probes Scalability for Powder Bed Fusion Layer-Wise Imaging.

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Summary

This study introduces a novel eddy current testing array probe for layer-wise quality control in metal additive manufacturing. The system utilizes cost-effective surface-mounted technology coils and simplified electronics for enhanced scalability and performance.

Keywords:
eddy current testingmetal additive manufacturingquality controlsensors arraysingle phase coherent demodulationsurface-mounted coils

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Area of Science:

  • Materials Science
  • Non-Destructive Testing
  • Additive Manufacturing

Background:

  • Quality control in powder bed fusion (PBF) metal additive manufacturing is crucial for ensuring component integrity.
  • Traditional eddy current testing (ECT) methods face challenges in scalability and sensor integration for layer-wise monitoring.

Purpose of the Study:

  • To develop a new eddy current testing array probe and readout electronics for layer-wise quality control in PBF metal additive manufacturing.
  • To explore scalable sensor solutions and minimalist signal processing techniques.

Main Methods:

  • Evaluation of small-sized, surface-mounted technology (SMT) coils as an alternative to magneto-resistive sensors.
  • Development of minimalist signal generation and demodulation strategies, including an adjustable single-phase coherent demodulation scheme.
  • Implementation of a simplified amplification and demodulation frontend with offset removal, vector amplification, and microcontroller-based digitalization.

Main Results:

  • Demonstrated the feasibility of using SMT coils, offering low cost, design flexibility, and easy integration.
  • Successfully materialized a 16-coil array probe with a 5 mm pitch and non-multiplexed digital readout electronics.
  • Achieved sensor frequencies up to 1.5 MHz, 12-bit digitalization resolution, and a 10 kHz sampling rate.

Conclusions:

  • The proposed eddy current testing array probe and electronics enable scalable, cost-effective layer-wise quality control for metal additive manufacturing.
  • The use of SMT coils and simplified demodulation presents a viable alternative for advanced non-destructive testing applications in additive manufacturing.