In-process Inspection (MTC Project Review)

Transcription

1 In-process Inspection (MTC Project Review) Dr Ben Dutton Metrology & NDT Research Theme Dissemination meeting for Metrology Fellowship 8 th December 2015

2 INTRODUCTION TO THE MTC 2

3 HIGH VALUE MANUFACTURING CATAPULT CENTRES 3

4 INTRODUCTION TO THE MTC Founded 2010 in Ansty, Coventry > 75 Industrial Members > 350 staff 1 of 7 centres in High Value Manufacturing (HVM) Catapult MTC has largest Metrology & NDT capability of centres 12 engineers 10 laboratory staff 4

5 RESEARCH THEMES AND WORKSHOP 5

6 METROLOGY & NDT (WHAT WE DO) Inspection solutions Validation of manufacturing processes Inspection selection and validation Automated inspection Inspection data management systems Strategic areas Computer-Aided Inspection Automated and in-line inspection 6

7 CRP PROJECT TECHNOLOGY MAPPING IN-SITU INSPECTION FOR AM 7

8 CRP HIGHLIGTS (AM PROCESSES CONSIDERED) Powder Bed Fusion (showing SLM) Direct Energy Deposition (showing blown powder) Courtesy: Courtesy: Salay Stannard, Cladding and Additive Manufacturing Using Laser Applied Power Processes, 2010, AWS New Welding Technologies 8

9 Aerospace Automotive Creative Industries Consumer goods Defence Electronics Energy Medical Prototyping Tooling & Casting CRP HIGHLIGTS (NEAR TO MARKET APPLICATIONS OF AM) Classification Material form Powder Bed Fusion (PBF) Powder Directed Energy Deposition (DED)/Cladding Powder feed Wire feed Courtesy: Additive Manufacturing SIG,

10 CRP HIGHLIGTS (LITERATURE REVIEW) Most common in-situ methods monitor the layer surface and have limited feedback-control: Optical Temperature sensors Surface scanners Less widely used technologies which have shown potential off-line and could be tried in-situ with capability to inspect between layers: Acoustic Radiographic Optical example: Arcam Q20 Courtesy: J. Schwerdtfeger, et al, Insitu flaw detection by IRimaging during electron beam melting, 2012, Rapid Prototyping Journal Acoustic example: MTC s laser ultrasound system 10

11 CRP HIGHLIGTS (IN-PROCESS INSPECTION TECHNOLOGY MAP) Note: NDT techniques do not necessarily detect all defect types 11

12 CRP HIGHLIGTS (TOWARDS AN IDEAL AM MACHINE) 12

13 AMAZE PROJECT 13

14 LASER ULTRASOUND (SYSTEM AT THE MTC) Adaptable to rough surfaces Ultrasound penetration depth can be optimised Adaptable to appropriate coverage A-scan, B-scan and C-scan capable Scan speeds of up to 1 m/min Research based unit with capability for integration 14

15 AMAZE PROJECT (LASER ULTRASOUND MEASUREMENTS ON SLM SAMPLES) Exploring In-Process Inspection Capability for Additive Layer Manufacturing Inspection of calibration samples with subsurface defects where images show: Scan process Sample with surface as built by SLM with side drilled holes B-scan of sample showing surface wave disturbance produced by corresponding drill holes Images courtesy of EU project AMAZE and University of Nottingham 15

16 ROLLS-ROYCE PROJECT 16

17 WELDING PROJECT (LASER ULTRASOUND SCAN SETUP) Scan direction Acknowledgement to John Boswell from Rolls-Royce for allowing to share these results. 17

18 WELDING PROJECT (LASER ULTRASOUND B-SCAN) B-scan and weld strip with notches 18 Acknowledgement to John Boswell from Rolls-Royce for allowing to share these results.

19 NDT STANDARDS FOR AM 19

20 ISO/TC 261 ASTM F42 NDT FOR AM PARTS (JG59) Best Practice Guide NDT for AM Parts Provide a best practice guide presenting current standards capable to cover some of the AM defect types and NDT methods potential to detect AM defects which are not covered by current standards. A comprehensive approach is taken to cover more sectors. Feeding defect information and review to ASTM E07 WK First draft under development. Point-of-Contact: Ben Dutton (MTC Limited) 20

21 ASTM E07 NON-DESTRUCTIVE TESTING (WK47031 ) Standard Guide for NDT of AM Metal Parts Used in Aerospace Applications Discusses the selection and application of established and emerging NDT procedures for AM metal parts throughout their life cycle. Complementary to WK Drafts are under development; CT, PCRT and UT sections begun. Point-of-Contact: Jess Waller (NASA) 21

22 OTHER CURRENT AND FUTURE IN-PROCESS NDT PROJECTS There are other current projects where in-process NDT is being pursued. There are several project proposals submitted and in the works. 22

23 CONTACT Dr Ben Dutton, Senior Research Engineer

24 DISCLAIMER: The data contained in this document contains proprietary information and it may not be copied or communicated to a third party or used for any other purpose than that which it was supplied without the MTC s prior written consent. MTC 2015