Additive manufactured (AM) metallic components have been increasingly applied across various industries. However, due to rapid temperature gradients and non-uniform thermal stresses during fabrication, defects such as cracks and pores are prone to occur. Laser ultrasonic testing faces challenges in achieving high-precision detection and imaging of surface defects on AM components, as strong scattering effects induced by surface roughness introduce considerable high-frequency noise and severely reduce the signal-to-noise ratio of defect echoes. To overcome this limitation, a combined VMD-TFM imaging method is proposed for the detection and characterization of submillimeter-scale surface defects on rough surfaces of AM Ti-6Al-4 V components. The approach introduces the Total Focusing Method (TFM)—originally developed for phased-array ultrasonic—into laser ultrasonic, where delay-compensated and coherently summed signals enable high-resolution, full-coverage imaging of the inspection area. In addition, Variational Mode Decomposition (VMD) is employed as a preprocessing step to denoise and reconstruct the effective signal modes, thereby suppressing high-frequency speckle and artifacts induced by surface roughness and enhancing the imaging precision for submillimeter defects. Validation through 3D surface metrology microscope shows that the spatial overlap between the VMD-TFM imaging and actual defect locations exceed 80 %, with the absolute diameter errors remain below 0.08 mm, confirming the high resolution and reliability of the proposed algorithm. This method provides a new pathway for accurate surface-quality evaluation and establishes a technical foundation for integrating laser ultrasonic testing into real-time monitoring and feedback control in additive manufacturing processes.
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