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A New Approach to Assessing the Quality of Aerospace Components

A sensing technology that can assess the quality of components in fields such as aerospace could transform UK industry.

A 3D printer used in this research. (Image: University of Bristol)

In a study, published in the Journal Waves in Random and Complex Media, researchers from the University of Bristol have derived a formula that can inform the design boundaries for a given component’s geometry and material microstructure.

A commercially viable sensing technology and associated imaging algorithm to assess the quality of such components currently does not exist. If the additive manufacturing (3D printing) of metallic components could satisfy the safety and quality standards in industries there could be significant commercial advantages in the manufacturing sector.

The key breakthrough is the use of ultrasonic array sensors, which are essentially the same as those used in medical imaging in, for example, creating images of babies in the womb. However, these new laser based versions would not require the sensor to be in contact with the material.

Author Professor Anthony Mulholland, Head of the School of Engineering Maths and Technology, explained: “There is a potential sensing method using a laser based ultrasonic array and we are using mathematical modeling to inform the design of this equipment ahead of its in situ deployment.”

The team built a mathematical model that incorporated the physics of ultrasonic waves propagating through a layered (as additively manufactured) metallic material, which took into account the variability one gets between each manufactured component.

The mathematical formula is made up of the design parameters associated with the ultrasonic laser and the nature of the particular material. The output is a measure of how much information will be produced by the sensor to enable the mechanical integrity of the component to be assessed. The input parameters can then be varied to maximize this information content.

It is hoped their discovery will accelerate the design and deployment of this proposed solution to this manufacturing opportunity.

Professor Mulholland added: “We can then work with our industry partners to produce a means of assessing the mechanical integrity of these safety critical components at the manufacturing stage.

“This could then lead to radically new designs (by taking full advantage of 3D printing), quicker and more cost effective production processes, and significant commercial and economic advantage to UK manufacturing.”

Now the team plan to use the findings to help their experimental collaborators who are designing and building the laser based ultrasonic arrays.

These sensors will then be deployed in situ by robotic arms in a controlled additive manufacturing environment. They will maximize the information content in the data produced by the sensor and create bespoke imaging algorithms to generate tomographic images of the interior of components supplied by their industry partners. Destructive means will then be employed to assess the quality of the tomographic images produced.

Professor Mulholland concluded: “Opening up 3D printing in the manufacture of safety critical components, such as those found in the aerospace industry, would provide significant commercial advantage to UK industry.

“The lack of a means of assessing the mechanical integrity of such components is the major blockage in taking this exciting opportunity forward. This study has built a mathematical model that simulates the use of a new laser based sensor, that could provide the solution to this problem, and this study will accelerate the sensor’s design and deployment.”

This research was performed by Anthony Mulholland and a team of researchers for the University of Bristol (Bristol BS8 1QU, United Kingdom). For more information, download the Technical Support Package (free white paper) below. ADTTSP-06242

Topics:
3D Printing & Additive Manufacturing Additive manufacturing Advanced manufacturing Computers Electronics Electronics & Computers Materials Mathematical models Quality control Quality management systems Research and development Robotics Safety critical systems Sensors Simulation and modeling
This Brief includes a Technical Support Package (TSP).
Document cover
A Probabilistic Approach to Modelling Ultrasonic Shear Wave Propagation in Locally Anisotropic Heterogeneous Media

(reference ADTTSP-06242) is currently available for download from the TSP library.

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    Magazine cover
    Aerospace & Defense Technology Magazine

    This article first appeared in the June, 2024 issue of Aerospace & Defense Technology Magazine (Vol. 9 No. 4).

    Read more articles from this issue here.

    Read more articles from the archives here.

    Overview

    The document presents a study on the propagation of ultrasonic shear waves in locally anisotropic heterogeneous media, focusing on a probabilistic modeling approach. The authors, Alistair S. Ferguson and colleagues, explore how these waves behave in materials with random layering and varying anisotropic properties, which is crucial for applications in non-destructive testing and material characterization.

    The research begins by constructing a probabilistic model for a monochromatic, horizontally polarized shear wave traveling through a medium composed of locally anisotropic layers. The internal microstructure of the medium interacts with the probing wave, leading to the generation of an incoherent coda wave. The orientation of the anisotropic material is modeled as varying randomly from layer to layer, following a Markov process.

    Using elastodynamic equations, the authors derive expressions for the forward and backward wave-modes, which describe the reflected and transmitted energy of the input wave. They develop a system of stochastic differential equations to address the wave-mode problem and utilize a limit theorem from stochastic analysis to derive a linear partial differential equation (the Fokker–Planck equation) for the probability density function associated with the transmitted power. This equation is solved numerically using a finite element package in Python.

    The numerical solutions allow the authors to investigate how material parameters affect the decay of energy in the coherent part of the transmitted wave. Notably, they calculate the mean and variance of the transmitted energy through a class of austenitic steel welds without resorting to costly Monte Carlo simulations. The study reveals that varying the degree of anisotropy significantly impacts the attenuation of coherent energy, providing insights into when a homogenization approach is valid based on the material's characteristics.

    The document concludes by emphasizing the importance of understanding wave propagation in complex materials, as it can enhance inspection methods and the overall effectiveness of additive manufacturing (AM). The authors suggest that future work could involve experimental testing of their theoretical findings, particularly in relation to the effects of component thickness on transmission coefficients.

    Overall, this research contributes to the field of ultrasonic testing and material science by providing a robust framework for modeling wave propagation in anisotropic and heterogeneous media, paving the way for improved inspection techniques and material evaluations.

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