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Eddy Current Sensors Optimization for Defect Detection in Parts Fabricated by Laser Powder Bed Fusion
Romain Saddoud1, Natalia Sergeeva-Chollet1, Michel Darmon1
1Université Paris-Saclay, CEA, List, F-91120 Palaiseau, France.
Sensors (Basel, Switzerland)
|May 13, 2023
Summary
Structural health monitoring (SHM) is crucial for additive manufactured parts. The eddy current method effectively detects defects, with isotropic sensors proving optimal for quality control and characterization.
Area of Science:
- Materials Science
- Non-Destructive Testing
- Manufacturing Engineering
Background:
- Additive manufacturing (AM) enables cost reduction and complex geometries but requires robust quality control.
- While in-process optical inspection detects defects during manufacturing, post-fabrication and in-service monitoring are essential for part integrity.
- Structural health monitoring (SHM) methods are needed to ensure the reliability of AM parts throughout their industrial lifespan.
Purpose of the Study:
- To investigate the efficacy of the eddy current (EC) method for non-destructive testing (NDT) of additively manufactured parts.
- To design and compare the performance of different EC sensors for defect detection.
- To identify the optimal EC sensor for characterizing surface and shallow defects in conductive materials produced by AM.
Main Methods:
- Utilized the CIVA non-destructive testing software package for sensor simulations.
- Designed and tested two types of EC sensors: a separate transmitter/receiver sensor and an isotropic sensor.
- Conducted simulation and experimental tests on parts fabricated via laser powder bed fusion (L-PBF).
- Evaluated sensor performance based on the detection of artificial defects (notches) and engraved features.
Main Results:
- Simulations and experiments demonstrated the suitability of the eddy current method for detecting surface and shallow defects in conductive AM parts.
- The isotropic sensor exhibited superior performance compared to the separate transmitter/receiver sensor in detecting and characterizing defects.
- The study successfully identified the optimal sensor configuration for NDT of L-PBF manufactured components.
Conclusions:
- The eddy current method is a viable technique for the structural health monitoring of additively manufactured parts.
- Isotropic eddy current sensors are recommended for the optimal detection and characterization of defects in conductive materials produced by L-PBF.
- Further research into EC-based SHM can enhance the reliability and safety of critical AM components.
