High-speed synchrotron X-ray imaging of melt pool dynamics during ultrasonic melt processing of Al6061
Not Available
36 MATERIALS SCIENCE↗
Engineering topics
Stobbe, David M.
Publications and source records attributed to Stobbe, David M..
Acoustoelastic characterization of plates using zero group velocity Lamb modes
Acoustoelasticity, a characteristic of material anharmonicity, gives rise to a link between wave propagation velocity and the stress state in materials. Ultrasonic techniques to monitor this coupling, particularly with high sensitivity and in a noncontact manner, can have widespread application both in the quantification of applied and residual stress and in the characterization of nonlinear material behavior through measurement of higher order elastic constants. Here, we use a laser ultrasonic technique to excite and detect zero group velocity (ZGV) Lamb wave resonances in aluminum plates under uniaxial loading. A laser line source is used to excite these resonances at different orientations with respect to the applied load, and the signals are detected using an interferometer. The effects of stress and source orientation on ZGV resonance frequencies are validated using the theory of acoustoelastic Lamb wave propagation. In addition, a model-based inversion technique is used to extract Murnaghan's third-order elastic constants from measurements of the stress dependence of the first two ZGV modes generated parallel and perpendicular to the applied load. Laser generation and detection of ZGV resonances is shown to be an effective and powerful approach for the noncontact and nondestructive acoustoelastic characterization of elastic waveguides.
36 MATERIALS SCIENCE↗
Demonstrating resonant ultrasound spectroscopy as a viable technique to characterize thermally conditioned high explosive materials
We present results of resonant ultrasound spectroscopy (RUS) measurements applied to granular high explosive materials at different bulk pressing densities and degree of thermal conditioning. The material chosen in this study is a ubiquitously used explosive material known as pentaerythritol tetranitrate (PETN), which is used commercially in civil and defense applications both as a binderized plastic bonded explosive material and an unbinderized neat material. However, changes in granular PETN bulk elastic properties due to thermal conditioning, which could have implications for better understanding environmental aging-related effects, have not been well studied even though it is believed that elasticity may play an important role in explosive material initiation mechanisms. Furthermore, monitoring elastic property changes in granular explosive pressings has not yet been demonstrated using RUS, which is an appealing non-destructive characterization tool that requires only dry point contact with the explosive material. To this end, we report the first study using RUS to quantify the elastic properties of binderized and neat PETN pressings as well as to quantify changes in elastic properties as a function of both thermal conditioning and bulk pressing density. Elastic stiffness coefficients, sometimes more commonly referred to as elastic constants, calculated from the RUS measurements on the different PETN-based materials show a significant increase for the post-conditioned samples compared to the pre-conditioned samples. This trend of increasing elastic properties with thermal conditioning was consistent for different density pressings, different thermal exposure conditions, and even different neat PETN pressings of differing average crystal sizes and/or specific surface areas.
36 MATERIALS SCIENCE↗
Laser ultrasonic imaging of subsurface defects with the linear sampling method
Laser ultrasonics is a remote nondestructive evaluation technique suitable for real-time monitoring of fabrication processes in semiconductor metrology, advanced manufacturing, and other applications where non-contact, high fidelity measurements are required. Here we investigate laser ultrasonic data processing approaches to reconstruct images of subsurface side drilled holes in aluminum alloy specimens. We demonstrate through simulation that the model-based linear sampling method (LSM) can perform accurate shape reconstruction of single and multiple holes and produce images with well-defined boundaries. We experimentally confirm that LSM produces images that represent the internal geometric features of an object, some of which may be missed by conventional imaging.
42 ENGINEERING↗
Multi-Defect Detection in Additively Manufactured Lattice Structures Using 3D Electrical Resistance Tomography
Cellular lattice structures possess high strength-to-weight ratios suitable for advanced lightweight engineering applications. However, their quality and mechanical performance can degrade because of defects introduced during manufacturing or in-service. Their complexity and small length scale features make defects difficult to detect using conventional nondestructive evaluation methods. Here we propose a current injection-based method, electrical resistance tomography (ERT), that can be used to detect damaged struts in conductive cellular lattice structures with their intrinsic electromechanical properties. The reconstructed conductivity distributions from ERT can reveal the severity and location of damaged struts without having to probe each strut. However, the low central sensitivity of ERT may result in image artifacts and inaccurate localization of damaged struts. To address this issue, this study introduces an absolute, high throughput, conductivity reconstruction algorithm for 3D ERT. The algorithm incorporates a strut-based normalized sensitivity map to compensate for lower interior sensitivity and suppresses reconstruction artifacts. Numerical simulations and experiments on fabricated representative cellular lattice structures were performed to verify the ability of ERT to quantitatively identify single and multiple damaged struts. The improved performance of this method compared with classical ERT was observed, based on greatly decreased imaging and reconstructed value errors.
36 MATERIALS SCIENCE↗
In Situ Optical Detection for Ultrasonic Characterization of Materials in a Mach 10 Hypersonic Wind Tunnel
Not Available
36 MATERIALS SCIENCE↗
Real-time laser ultrasonic monitoring of laser-induced thermal processes
Abstract Intra- and inter-layer integrity of components fabricated with advanced manufacturing techniques, such as laser powder bed fusion, is dependent upon rapid heating, melting, and solidification processes. There is a need for new techniques to provide in situ feedback of these processes. Here a laser-based ultrasonic technique to probe thermal effects induced by a high-power continuous wave laser in titanium samples is described. Numerical simulations were performed to show that, for a spatially uniform heating beam, laser-induced surface acoustic waves are strongly influenced by surface heating conditions, are dispersive in the case of rapid heating, and that an abrupt velocity reduction happens upon the onset of surface melting. Furthermore, laser-based ultrasound experimental results which monitor the transient change of surface wave travel time associated with high power laser surface heating are provided. A pulsed laser is used to generate high frequency surface acoustic waves that propagate through the laser-heated region and are detected using a photorefractive crystal-based interferometer. Qualitative agreement is observed between theory and experiment with both showing a rapid reduction in the surface wave velocity at the onset of illumination and further decrease in surface wave velocity associated with melting. It is demonstrated that changes in the surface wave velocity can be used to track local heating and detect the onset of surface melting in real time.
36 MATERIALS SCIENCE↗
Observation of asymmetric explosive density evolution in the deflagration-to-detonation transition for porous explosives
We report deflagration-to-detonation transition phenomena in cylindrical columns of porous explosives based on octahydro-1,3,5,7-tetranitro-1,3,5,7-tetrazocine (HMX). The HMX powder and LX-14 (95.5 wt. % HMX and 4.5 wt. % estane polyurethane) prills were observed with high-speed cameras and flash x rays under conditions that allow for precise scaling and registration of the recorded images. These experimental results test the conventional assumption of axisymmetric, effective one-dimensional burning. Polycarbonate confinement tubes allowed this direct imaging with steel spheres employed as radio-opaque fiducials. Spheres embedded in the explosive column revealed the displacement of the explosive prior to deflagration. X-ray and fast camera images show that a dense plug of compact explosive develops ahead of the deflagration front. The internal fiducials register both internal changes in the plug and changes in the position between successive x-ray images. Tantalum witness strips placed on the inner wall of the explosive channel revealed radial expansion of the tube bore at successive x-ray exposures, indicating the internal pressure of about 100 MPa just before detonation. Images indicate that the deflagration is not only asymmetric but also involves newly observed transient phenomena just before detonation. Furthermore, we typically see a brief but continuous increase in deflagration speed and the formation of a deflagration channel that bypasses the plug just prior to detonation. We hypothesize that these phenomena play an important role in the deflagration-to-detonation transition itself.
37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
In-situ monitoring for liquid metal jetting using a millimeter-wave impedance diagnostic
Abstract This article presents a millimeter-wave diagnostic for the in-situ monitoring of liquid metal jetting additive manufacturing systems. The diagnostic leverages a T-junction waveguide device to monitor impedance changes due to jetted metal droplets in real time. An analytical formulation for the time-domain T-junction operation is presented and supported with a quasi-static full-wave electromagnetic simulation model. The approach is evaluated experimentally with metallic spheres of known diameters ranging from 0.79 to 3.18 mm. It is then demonstrated in a custom drop-on-demand liquid metal jetting system where effective droplet diameters ranging from 0.8 to 1.6 mm are detected. Experimental results demonstrate that this approach can provide information about droplet size, timing, and motion by monitoring a single parameter, the reflection coefficient amplitude at the input port. These results show the promise of the impedance diagnostic as a reliable in-situ characterization method for metal droplets in an advanced manufacturing system.
42 ENGINEERING↗