Duarte, VR, Rodrigues TA, Machado MA.
2021.
Benchmarking of Nondestructive Testing for Additive Manufacturing. 3D Printing and Additive Manufacturing.
AbstractDefect detection in additive manufacturing (AM) is of paramount importance to improve the reliability of products. Nondestructive testing is not yet widely used for defect detection. The main challenges are a lack of standards and methods, the types and location of defects, and the complex geometry of many parts. During selective laser melting (SLM), several types of defects can occur such as porosity, cracking, and lack of fusion. In this study, several nondestructive tests were conducted in a highly complex shaped part in AISI 316L stainless steel with real defects manufactured by SLM. Two additional artificial defects (one horizontal and one flat bottom hole) were produced and the defect detectability was evaluated. The techniques used were as follows: dye penetrant, infrared thermography, immersion ultrasonic, eddy current, and X-ray microcomputed tomography to assess different types of defects in the as-built part. We conclude that no single technique can detect every type of defect, although multiple techniques provide complementary and redundant information to critically evaluate the integrity of the parts. This approach is fundamental for improving the reliability of defect detection, which will help expand the potential for using AM to produce parts for critical structural applications.
Machado, MA, Antin K-N, Rosado LS, Vilaça P, Santos TG.
2019.
Contactless high-speed eddy current inspection of unidirectional carbon fiber reinforced polymer. Composites Part B: Engineering. 168:226-235.
AbstractThis paper presents the development and the results of a customized eddy current (EC) non-destructive testing (NDT) system for highly demanding online inspection conditions. Several planar eddy current array probes were designed, numerically simulated and experimentally compared for the inspection of low conductivity unidirectional carbon fibre reinforced polymer (CFRP) ropes. The inspections were performed using a dedicated scanner device at 4 m/s with 3 mm probe lift-off where defects under 1 mm were detected with an excellent SNR. Different defect morphologies and sizes, such as broken fibres and lateral cuts, were successful detected and compared to conventional probes.
Santos, TG, Miranda RM, Vieira TM, Farinha RA, Ferreira TJ, Quintino L, Vilaça P, de Carvalho CCCR.
2016.
Developments in micro- and nano-defects detection using bacterial cells. NDT & E International. 78:20-28.
AbstractThis paper describes improvements to the Nondestructive Testing (NDT) technique recently proposed, based on the use of bacterial cell suspensions to identify micro- and nano-surface defects. New bacterial strains were used with magnetic fields to improve bacteria mobility. Different materials and defect morphologies were tested, including nanoindentation defects, micro-powder injection moulding components and micro-laser welding. Nanoindentations with 0.6 µm depth and 5.3 µm side length were successfully detected. Bacterial cells allow identifying different topographic attributes of the surfaces, such as roughness. Cracks of about 0.5 µm wide and 10 µm depth in a reference test block Type 1 were successfully detected.
Antin, K-N, Machado MA, Santos TG, Vilaça P.
2019.
Evaluation of Different Non-destructive Testing Methods to Detect Imperfections in Unidirectional Carbon Fiber Composite Ropes. Journal of Nondestructive Evaluation. 38(23)
AbstractOnline monitoring of carbon fiber reinforced plastic (CFRP) ropes requires non-destructive testing (NDT) methods capable of detecting multiple damage types at high inspection speeds. Three NDT methods are evaluated on artificial and realistic imperfections in order to assess their suitability for online monitoring of CFRP ropes. To support testing, the microstructure and electrical conductivity of a carbon fiber rope is characterized. The compared methods are thermography via thermoelastic stress analysis, ultrasonic testing with commercial phased array transducers, and eddy current testing, supported by tailor-made probes. While thermoelastic stress analysis and ultrasonics proved to be accurate methods for detecting damage size and the shape of defects, they were found to be unsuitable for high-speed inspection of a CFRP rope. Instead, contactless inspection using eddy currents is a promising solution for real-time online monitoring of CFRP ropes at high inspection speeds.