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Thermal Calibration of Ratiometric, On-Axis Melt Pool Monitoring Photodetector System Using Tungsten Strip Lamp 基于钨带灯的比率式轴上熔池监测光电探测器系统的热校准
IF 0.6 4区 材料科学 Q4 MATERIALS SCIENCE, CHARACTERIZATION & TESTING Pub Date : 2022-04-01 DOI: 10.32548/2022.me-04271
Brett G. Diehl, A. Castro, Lars Jaquemetton, D. Beckett
In situ melt pool monitoring is a set of technologies widely deployed on industrial, metals-based laser powder bed fusion (LPBF) additive manufacturing (AM) systems. This study investigates the use of a calibrated tungsten ribbon lamp as a reference standard to calibrate a photodetector based, on-axis melt pool monitoring system. Calibration demonstrates two functions: (a) enable a reference for measuring and ensuring system repeatability, and (b) enable reference to physical temperature values based on the measured photodetector signals. The second function is explored in this paper. A regression-based model is derived based on bichromatic Planck thermometry theory. The calibrated tungsten lamp is then placed within a LPBF system, and resulting photodetector signals are measured at different lamp temperature set points to calibrate the model. Finally, several additional characterization tests and their results are presented verifying the temporal response of the lamp, measurement noise as a function of sampling time, and spectroscopic measurements of the LPBF optics and their potential effect on temperature calibration. A framework is also developed to normalize temperature readings across the build plate to remove location-dependent optical artifacts.
熔池原位监测是一套广泛应用于工业金属激光粉末床聚变(LPBF)增材制造(AM)系统的技术。本研究调查了使用校准的钨带灯作为参考标准来校准基于光电探测器的轴熔池监测系统。校准演示了两个功能:(a)启用用于测量和确保系统可重复性的参考,以及(b)启用基于测量的光电探测器信号的物理温度值的参考。本文探讨了第二个函数。基于双色普朗克测温理论,推导了一个基于回归的模型。然后将校准后的钨灯放置在LPBF系统中,并在不同的灯温度设定点测量得到的光电探测器信号,以校准模型。最后,给出了几个额外的表征测试及其结果,验证了灯的时间响应、作为采样时间函数的测量噪声、LPBF光学器件的光谱测量及其对温度校准的潜在影响。还开发了一个框架来规范整个构建板的温度读数,以去除与位置相关的光学伪影。
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引用次数: 1
Thermocouple Process Monitoring for Additive Manufacturing 增材制造热电偶过程监控
IF 0.6 4区 材料科学 Q4 MATERIALS SCIENCE, CHARACTERIZATION & TESTING Pub Date : 2022-04-01 DOI: 10.32548/2022.me-04243
S. Kenderian, Tait D. McLouth, Dhruvish Y. Patel, Julian R. Lohser
To understand the thermal history of parts manufactured in a laser powder bed fusion system, eight thermocouple sensors were imbedded at key locations with respect to the parts being built. The design comprised eight vertical cylinders 2.54 cm (1 in.) and 1.27 cm (0.5 in.) in diameter and four 2.54 cm (1 in.) horizontal cylinders. The temperature signature collected at the eight locations reveals the time intervals of depositing and melting each layer and the cooling trend associated with the stoppage required for filter cleaning. The temperature profile also reveals a fast rate of heat accumulation at the start of the process. As more layers are melted and the part becomes taller, the dissipation path for heat deposited by the laser increases prior to reaching the build plate. The heat accumulation, therefore, increases rapidly at first, then decreases, plateaus, and then drops slightly toward the end. Distortions due to residual stresses and resultant part separation from the build plate can be deduced from the thermal signature as detected by the thermocouple sensors. This allows the manufacturer to make adjustments or abort the process if necessary. Otherwise, these distortions that render the part a reject are discovered hours or days later upon completion of the additively manufactured part.
为了了解在激光粉末床熔合系统中制造的部件的热历史,在正在制造的部件的关键位置嵌入了八个热电偶传感器。该设计包括8个直径分别为2.54厘米和1.27厘米的垂直圆柱体和4个直径为2.54厘米的水平圆柱体。在八个地点收集的温度特征揭示了沉积和熔化每层的时间间隔以及与过滤器清洁所需停机相关的冷却趋势。温度分布也揭示了在过程开始时的快速热积累速率。随着更多的层被熔化,部件变得更高,激光沉积的热的耗散路径在到达构建板之前增加。因此,热积累在开始时迅速增加,然后减少,趋于稳定,然后在接近尾声时略有下降。根据热电偶传感器检测到的热特征,可以推断出由于残余应力和由此产生的部件与构建板分离而产生的变形。这允许制造商在必要时进行调整或中止该过程。否则,这些使零件成为废品的变形会在增材制造零件完成后的数小时或数天内被发现。
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引用次数: 0
Ultrasonic Characterization of Porosity in Components Made by Binder Jet Additive Manufacturing 粘结剂喷射增材制造组件孔隙率的超声表征
IF 0.6 4区 材料科学 Q4 MATERIALS SCIENCE, CHARACTERIZATION & TESTING Pub Date : 2022-04-01 DOI: 10.32548/2022.me-04266
O. Cook, Nancy Huang, R. Smithson, C. Kube, A. Beese, A. Argüelles
Binder jet metallic additive manufacturing (AM) is a popular alternative to powder bed fusion and directed energy deposition because of lower costs, elimination of thermal cycling, and lower energy consumption. However, like other metallic AM processes, binder jetting is prone to defects like porosity, which decreases the adoption of binder-jetted parts. Binder-jetted parts are sometimes infiltrated with a low melting temperature metal to fill pores during sintering; however, the infiltration is impacted by the part geometry and infiltration environment, which can cause infill nonuniformity. Furthermore, using an infiltration metal creates a complicated multiphase microstructure substantially different than common wrought materials and alloys. To bring insight to the binder jet/infiltration process toward part qualification and improved part quality, spatially dependent ultrasonic wave speed and attenuation techniques are being applied to help characterize and map porosity in parts made by binder jet AM. In this paper, measurements are conducted on binder-jetted stainless steel and stainless steel infiltrated with bronze samples. X-ray computed tomography (XCT) is used to provide an assessment of porosity.
粘结剂喷射金属增材制造(AM)是粉末床熔融和定向能沉积的一种流行的替代方法,因为成本更低,消除了热循环,能耗更低。然而,与其他金属增材制造工艺一样,粘结剂喷射容易出现气孔等缺陷,从而降低了粘结剂喷射件的采用率。在烧结过程中,粘结剂喷射件有时会渗入低熔点金属以填充气孔;然而,入渗受零件几何形状和入渗环境的影响,会造成充填不均匀性。此外,使用渗透金属会产生复杂的多相微观结构,这与普通的变形材料和合金有很大的不同。为了深入了解粘结剂喷射/渗透过程,以确定零件质量并提高零件质量,应用了空间相关的超声波速度和衰减技术,以帮助表征和绘制粘结剂喷射AM制造的零件的孔隙度。本文对粘结剂喷射不锈钢和青铜浸渍不锈钢试样进行了测试。x射线计算机断层扫描(XCT)用于评估孔隙度。
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引用次数: 7
Characterization of Wall-Loss Defects in Curved GFRP Composites Using Pulsed Thermography 利用脉冲热成像技术表征弯曲GFRP复合材料的壁损缺陷
IF 0.6 4区 材料科学 Q4 MATERIALS SCIENCE, CHARACTERIZATION & TESTING Pub Date : 2022-03-01 DOI: 10.32548/2022.me-04160
R. Gomathi, M. Ashok, M. Menaka, B. Venkatraman
Curved glass fiber–reinforced polymer (GFRP) composites are superior to alloy-steel pipes due to their excellent corrosive resistance properties, finding wide applications in the transportation of petrochemicals, chemical storage tanks, and power and water-treatment plants. Among the defects found in GFRP pipes, internal pitting or wall loss is one of the most severe, caused by material deterioration and the friction of small particles in the transfer fluid. This study investigates these in-service discontinuities using a pulsed thermal nondestructive evaluation technique. The paper focuses on the quantification of defect depth using the temperature peak contrast derivative and defect sizing using the full width at half maximum method. Further, the paper investigates the ability of pulsed thermography to estimate pitting or wall-loss defects at various depths and sizes through simulation and experimentation. Thermographic signal reconstruction images are used for quantification of defects at a deeper depth. The results of the present study are then compared with well-established ultrasonic C-scan results.
弯曲玻璃纤维增强聚合物(GFRP)复合材料由于其优异的耐腐蚀性而优于合金钢管道,在石油化工产品、化学品储罐、发电厂和水处理厂的运输中得到广泛应用。在GFRP管道中发现的缺陷中,内部点蚀或壁损是最严重的缺陷之一,这是由材料劣化和传递流体中小颗粒的摩擦引起的。本研究使用脉冲热无损评估技术来研究这些在役不连续现象。本文重点研究了用温度峰对比导数定量缺陷深度和用半最大值全宽度法定量缺陷尺寸。此外,本文通过模拟和实验研究了脉冲热成像在不同深度和尺寸下估计点蚀或壁损缺陷的能力。热成像信号重建图像用于在更深的深度缺陷的量化。然后将本研究结果与已建立的超声c扫描结果进行比较。
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引用次数: 1
Study on Nonlinear Lamb Wave Test for Invisible Impact Damage on CFRP Laminates CFRP复合材料不可见冲击损伤非线性兰姆波试验研究
IF 0.6 4区 材料科学 Q4 MATERIALS SCIENCE, CHARACTERIZATION & TESTING Pub Date : 2022-03-01 DOI: 10.32548/2022.me-04191
Chenggeng Li, Zhenhua Chen, Wei-bing Chen, Chao-feng Lu
The impact damage imposed on carbon fiber–reinforced polymer (CFRP) materials used in aircraft fuselage may seriously affect flight safety. An ultrasonic testing method can be used to inspect for damage; however, in some cases of invisible or barely visible impact damage, linear ultrasound may not provide a clear indication of the underlying damage. Accordingly, a nonlinear Lamb wave technique was developed in this study to detect invisible impact damage (IID). First, a nonlinear Lamb wave testing platform was set, as well as damage areas with different impact energies. Second, the anisotropic propagation of Lamb waves was studied to determine the wave mode and the distribution of the transducers, and the linear parameters of the Lamb waves were determined. Last, three types of characteristic parameters of nonlinear Lamb waves were obtained for damage detection. As revealed from the results, the linear ultrasonic parameters of A0 mode Lamb waves can be applied to the detection of macro surface cracks, and the frequency shift, relative nonlinearity coefficient (RNC), and fluctuation coefficient of RNCs are highly sensitive to the detection of IID. Thus, a combination of nonlinear S0 Lamb waves and linear A0 Lamb waves can be used for IID and macro surface crack detection, respectively.
飞机机身中使用的碳纤维增强聚合物(CFRP)材料受到的冲击损伤可能会严重影响飞行安全。超声波检测方法可用于检查损坏情况;然而,在一些不可见或几乎不可见的冲击损伤的情况下,线性超声可能无法提供潜在损伤的明确指示。因此,本研究开发了一种非线性兰姆波技术来检测不可见冲击损伤(IID)。首先,建立了一个非线性兰姆波测试平台,以及不同冲击能量的损伤区域。其次,对兰姆波的各向异性传播进行了研究,确定了换能器的波型和分布,并确定了兰姆波的线性参数。最后,获得了三类非线性兰姆波的特征参数,用于损伤检测。结果表明,A0型兰姆波的线性超声参数可以应用于宏观表面裂纹的检测,RNC的频移、相对非线性系数(RNC)和波动系数对IID的检测高度敏感。因此,非线性S0兰姆波和线性A0兰姆波的组合可以分别用于IID和宏观表面裂纹检测。
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引用次数: 1
Improvement of Exotic Material Verification Using XRF 用XRF验证外来物质的改进
IF 0.6 4区 材料科学 Q4 MATERIALS SCIENCE, CHARACTERIZATION & TESTING Pub Date : 2022-03-01 DOI: 10.32548/2022.me-04268
Joshua H. Litofsky
While various common alloys, such as steels, titaniums, and more recently aluminums, have been tested and inspected using X-ray fluorescence spectroscopy (XRF) for decades, uncommon and niche alloys can produce surprising and unusual results. The ability to identify the base metal, major alloying elements, and trace materials in these alloys is critical to XRF testing and inspection procedures. Modern XRF instruments and software can quickly and easily characterize standard and common alloys, such as low-carbon steel, grade 5 titanium, and 6000 series aluminum; detected signals from the metals are generally discrete and strongly pronounced. Less common alloys, such as nickel superalloys and uraniums, present a greater analytical hurdle for rapid on-site testing, grading, and inspection. These exotic materials contain either weaker signals from the alloying elements or nonunique signatures, preventing accurate quantification. Standardization adjustments through software improvements increase the testing accuracy for these uncommon alloys, bringing their results in line with those from more traditional alloys. By modulating the detection energies of interest, the robust calculation can greatly surpass standard, out-of-the-box performance without the need for any inspector input. These improvements can provide greater inspection accuracy on a wider variety of rare and valuable alloys into the future.
尽管几十年来,各种常见的合金,如钢、钛和最近的铝,已经使用X射线荧光光谱(XRF)进行了测试和检查,但不常见和小众的合金可能会产生令人惊讶和不寻常的结果。识别这些合金中的基底金属、主要合金元素和微量材料的能力对XRF测试和检查程序至关重要。现代XRF仪器和软件可以快速轻松地表征标准和常见合金,如低碳钢、5级钛和6000系列铝;检测到的来自金属的信号通常是离散的并且非常明显。不太常见的合金,如镍超合金和铀,为快速现场测试、分级和检查提供了更大的分析障碍。这些外来材料要么含有来自合金元素的较弱信号,要么含有非唯一特征,从而妨碍了准确的量化。通过软件改进进行标准化调整,提高了这些不常见合金的测试精度,使其结果与更传统的合金一致。通过调节感兴趣的检测能量,鲁棒计算可以大大超过标准的开箱即用性能,而不需要任何检查员输入。这些改进可以在未来为更广泛的稀有和有价值的合金提供更高的检测精度。
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引用次数: 0
Image Processing with Deep Learning: Surface Defect Detection of Metal Gears through Deep Learning 深度学习的图像处理:通过深度学习检测金属齿轮的表面缺陷
IF 0.6 4区 材料科学 Q4 MATERIALS SCIENCE, CHARACTERIZATION & TESTING Pub Date : 2022-02-01 DOI: 10.32548/2022.me-04230
Yavuz Selim Balcioglu, B. Sezen, M. S. Gok, Sezai Tunca
Intelligent production requires improved data analytics and better technological possibilities to improve system performance and decision making. With the widespread use of the machine learning process, a growing need has arisen for processing extensive production data, equipped with high volumes, high speed, and high diversity. At this point, deep learning provides advanced analysis tools for processing and analyzing extensive production data. The deep convolutional neural network (DCNN) displays state-of-the-art performance on many grounds, including metal manufacturing surface defect detection. However, there is still space for improving the defect detection performance over generic DCNN models. The proposed approach performed better than the associated methods in the particular area of surface crack detection. The defect zones of disjointed results are classified into their unique classes by a DCNN. The experimental outcomes prove that this method meets the durability and efficiency requirements for metallic object defect detection. In time, it can also be extended to other detection methods. At the same time, the study will increase the accuracy quality of the features that can make a difference in the deep learning method for the detection of surface defects.
智能生产需要改进的数据分析和更好的技术可能性来提高系统性能和决策。随着机器学习过程的广泛使用,人们越来越需要处理大量、高速和高多样性的生产数据。在这一点上,深度学习为处理和分析大量生产数据提供了先进的分析工具。深度卷积神经网络(DCNN)在许多方面表现出最先进的性能,包括金属制造表面缺陷检测。然而,与通用DCNN模型相比,缺陷检测性能仍有改进的空间。在表面裂纹检测的特定领域,所提出的方法比相关方法表现得更好。通过DCNN将不相交结果的缺陷区域划分为其唯一的类别。实验结果证明,该方法满足金属物体缺陷检测的耐久性和效率要求。随着时间的推移,它还可以扩展到其他检测方法。同时,该研究将提高特征的准确性和质量,这些特征可以在深度学习方法中对表面缺陷的检测产生影响。
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引用次数: 0
Mechanics of Neutron Radiation and Applications in the Field 中子辐射力学及其在野外的应用
IF 0.6 4区 材料科学 Q4 MATERIALS SCIENCE, CHARACTERIZATION & TESTING Pub Date : 2022-02-01 DOI: 10.32548/2022.me-04265
Willow Ascenzo
This article is a companion piece for my first article published in the April 2020 issue of Materials Evaluation (https://doi.org/10.32548/2020.me-04136). While that article provided a broad overview of neutron radiography, this article delves deeper into the mechanics of neutron radiation and provides more examples of its applications in the field of nondestructive testing.
这篇文章是我发表在2020年4月号《材料评估》上的第一篇文章的配套文章(https://doi.org/10.32548/2020.me-04136)。虽然这篇文章对中子射线照相术进行了广泛的概述,但本文更深入地研究了中子辐射的力学,并提供了更多其在无损检测领域应用的例子。
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引用次数: 0
The Mysteries of the Shroud of Turin 都灵裹尸布之谜
IF 0.6 4区 材料科学 Q4 MATERIALS SCIENCE, CHARACTERIZATION & TESTING Pub Date : 2022-02-01 DOI: 10.32548/2022.me-02022
R. Rucker
In 1931, a professional photographer named Giuseppe Enri pointed his camera at a piece of cloth called the Shroud of Turin. How was this image formed? When was it made? Who made it? Is this an image of a real person? Could this be an image of the man known as Jesus Christ? Could this be the authentic burial cloth of Jesus? These are just a few of the questions that arise. This article provides an overview of the Shroud, including its images, history, materials, and previous testing. It also includes the author’s hypothesis to explain the main mysteries of the Shroud, including image formation, carbon dating, and features of the blood on the Shroud. The purpose of this article is to encourage the development of a program for future testing of the Shroud. There are rumors the Shroud may go on exhibition in Turin, Italy, in 2025. To help obtain authorization for further scientific testing possibly following the exhibition in 2025, a comprehensive testing program should be developed for the Shroud to take advantage of advances in technology since the last extensive testing in 1978.
1931年,一位名叫朱塞佩·恩里的专业摄影师将相机对准了一块名为“都灵裹尸布”的布。这个图像是如何形成的?它是什么时候做的?是谁做的?这是真人的照片吗?这可能是一个被称为耶稣基督的人的形象吗?这会是耶稣的真迹吗?这些只是出现的几个问题。本文概述了裹尸布,包括其图像、历史、材料和以前的测试。它还包括作者解释裹尸布主要奥秘的假设,包括图像形成、碳年代测定和裹尸布上血液的特征。这篇文章的目的是鼓励为裹尸布的未来测试开发一个程序。有传言说裹尸布可能在2025年在意大利都灵展出。为了帮助获得可能在2025年展览后进行进一步科学测试的授权,应该为裹尸布制定一个全面的测试计划,以利用自1978年上次大规模测试以来的技术进步。
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引用次数: 2
NDE Outlook: Informatization of NDT and NDE 无损检测展望:无损检测和无损检测的信息化
IF 0.6 4区 材料科学 Q4 MATERIALS SCIENCE, CHARACTERIZATION & TESTING Pub Date : 2022-01-01 DOI: 10.32548/2022.me-800122
Johannes Ludwig Vrana
Informatization is defined as the processby which information technologies,such as the World Wide Web and othercommunication technologies, havetransformed economic and social relationsto such an extent that cultural andeconomic barriers are minimized.What does this mean for nondestructivetesting and evaluation (NDT/E)? Inshort: informatization in NDT and NDEhas happened and will continue tohappen, independent of whether individualsor companies like it ornot. However, we can shapeit—together.
信息化被定义为信息技术,如万维网和其他通信技术,改变经济和社会关系,使文化和经济障碍最小化的过程。这对无损检测和评估(NDT/E)意味着什么?总之:无损检测和无损检测的信息化已经发生并将继续发生,无论个人或公司是否喜欢。然而,我们可以一起塑造它。
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引用次数: 0
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