A Review of Non-Destructive Testing (NDT) Techniques for Defect Detection: Application to Fusion Welding and Future Wire Arc Additive Manufacturing Processes.

In Wire and Arc Additive Manufacturing (WAAM) and fusion welding, various defects such as porosity, cracks, deformation and lack of fusion can occur during the fabrication process. These have a strong impact on the mechanical properties and can also lead to failure of the manufactured parts during service. These defects can be recognized using non-destructive testing (NDT) methods so that the examined workpiece is not harmed. This paper provides a comprehensive overview of various NDT techniques for WAAM and fusion welding, including laser-ultrasonic, acoustic emission with an airborne optical microphone, optical emission spectroscopy, laser-induced breakdown spectroscopy, laser opto-ultrasonic dual detection, thermography and also in-process defect detection via weld current monitoring with an oscilloscope. In addition, the novel research conducted, its operating principle and the equipment required to perform these techniques are presented. The minimum defect size that can be identified via NDT methods has been obtained from previous academic research or from tests carried out by companies. The use of these techniques in WAAM and fusion welding applications makes it possible to detect defects and to take a step towards the production of high-quality final components.

Resolution Limits in Photoacoustic Imaging Caused by Acoustic Attenuation.

In conventional photoacoustic tomography, several effects contribute to the loss of resolution, such as the limited bandwidth and the finite size of the transducer, or the space-dependent speed of sound. They can all be compensated (in principle) technically or numerically. Frequency-dependent acoustic attenuation also limits spatial resolution by reducing the bandwidth of the photoacoustic signal, which can be numerically compensated only up to a theoretical limit given by thermodynamics. The entropy production, which is the dissipated energy of the acoustic wave divided by the temperature, turns out to be equal to the information loss, which cannot be compensated for by any reconstruction method. This is demonstrated for the propagation of planar acoustic waves in water, which are induced by short laser pulses and measured by piezoelectric acoustical transducers. It turns out that for water, where the acoustic attenuation is proportional to the squared frequency, the resolution limit is proportional to the square root of the distance and inversely proportional to the square root of the logarithm of the signal-to-noise ratio. The proposed method could be used in future work for media other than water, such as biological tissue, where acoustic attenuation has a different power-law frequency dependence.

Quasi-balanced two-wave mixing interferometer for remote ultrasound detection.

We present an improved detection scheme for a two-wave mixing interferometer with a Bi12SiO20 crystal. The proposed detection scheme allows quasi-balanced detection of ultrasonic signals whereby electrical disturbances are suppressed. Quasi-balancing is achieved by changing the polarity of the high voltage at the photorefractive crystal, leading to an inversion of the optical interference signal, in combination with inversion of the detector signal using a signal inverter before the data acquisition device. The polarity of the high voltage is changed by utilizing an H-bridge consisting of five high-voltage relays. Microcontrollers are used to synchronize the reversion of the high voltage at the photorefractive crystal and the inversion of the measured signals. We demonstrate remote measurement of ultrasonic waves and shown that electrical disturbances are suppressed using the quasi-balanced mode.

Broadband high-frequency measurement of ultrasonic attenuation of tissues and liquids.

The ongoing expansion of the frequency range used for ultrasonic imaging requires increasing attention to the acoustic attenuation of biomaterials. This work presents a novel method for measuring the attenuation of tissue and liquids in vitro on the basis of single transmission measurements. Ultrasound was generated by short laser pulses directed onto a silicon wafer. In addition, unfocused piezoelectric transducers with a center frequency of 50 MHz were used to detect and emit ultrasound. The laser ultrasound method produces signals with a peak frequency of 30 MHz. In comparison to piezoelectric generation, pulse laser excitation provides approximately 4 times higher amplitudes and 20% larger bandwidth. By using two excitation methods in succession, the attenuation parameters of porcine fat samples with thicknesses in the range of 1.5 to 20 mm could be determined quantitatively within a total frequency range of 5 to 45 MHz. The setup for liquid measurements was tested on samples of human blood and olive oil. Our results are in good agreement with reports in literature.

Downstream Fabry-Perot interferometer for acoustic wave monitoring in photoacoustic tomography.

An optical detection setup consisting of a focused laser beam fed into a downstream Fabry-Perot interferometer (FPI) for demodulation of acoustically generated optical phase variations is investigated for its applicability in photoacoustic tomography. The device measures the time derivative of acoustic signals integrated along the beam. Compared to a setup where the detection beam is part of a Mach-Zehnder interferometer, the signal-to-noise ratio of the FPI is lower, but the image quality of the two devices is similar. Using the FPI in a photoacoustic tomograph allows scanning the probe beam around the imaging object without moving the latter.

Liver surgery planning using virtual reality.

In liver surgery planning, 2D and desktop-based 3D systems offer surgeons limited assistance. By using VR technology to liberate 3D from 2D input devices such as the mouse and keyboard, this surgery planning system better supports surgeons. User studies show that the system is both effective and easy to use.