Engineering topics
Tringe, Joseph W.
Publications and source records attributed to Tringe, Joseph W..
Towards microwave volumetric additive manufacturing: Generation of a computational multi-physics model for localized curing
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System and method for microwave volumetric additive manufacturing
The present disclosure relates to a volumetric additive manufacturing system for forming a structure from a volume of resin using microwave energy. The system makes use of an electronic controller and at least one beam forming algorithm accessible by the electronic controller for generating information relating to an amplitude and a time delay for forming a microwave signal, where the microwave signal will be used in irradiating a build volume, and where the build volume is formed by the volume of resin. A microwave signal generating subsystem is included which is responsive to the information generated by the beam forming algorithm, and which generates a microwave signal using the amplitude and the time delay determined by the beam forming algorithm. An antenna is used to receive the microwave signal and project the microwave signal as a microwave beam, in accordance with the amplitude and time delay, into the build volume to form the structure.
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.
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.
Fused x-ray and fast neutron CT reconstruction for imaging large and dense objects
Megavolt x-ray computed tomography (CT) is a powerful tool for three-dimensional characterization. However, its utility is limited for large objects composed of high-atomic number (Z) materials, where x rays fail to penetrate. Information from fast neutron CT (FNCT) can complement x-ray CT reconstructions since fast neutrons can more readily penetrate high-Z objects. In this work, we demonstrate a method for combining FNCT and x-ray CT data to create a single reconstruction, more accurate than could be achieved with either x rays or fast neutrons alone. The algorithm was tested on an exemplar comprising multiple concentric, nested cylinders of different materials. Simulated and empirical x-ray CT data were acquired for the exemplar using a 9 MV bremsstrahlung spectrum. Additional simulated and empirical FNCT data were acquired using an accelerator based fast neutron source. The FNCT data were used to synthesize x-ray CT data and augment the x-ray CT data missing due to lack of penetration. This approach mitigates artifacts that would otherwise negatively affect the accuracy and resolution of a single-modality reconstructed volume.
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.
Fourier method for 3-dimensional data fusion of X-ray Computed Tomography and ultrasound
X-ray Computed Tomography (CT) is essential for nondestructive inspection of many manufactured components but is susceptible to various forms of artifacts and noise. In particular, multi-detector row cone-beam CT systems can suffer from so called “cone-beam” artifacts and partial volume effects, particularly on planar edges at the periphery of the field of view in the cone angle dimension. Uni-directional ultrasonic testing methods generally have extremely accurate in-plane depth resolution but poorer lateral resolution due to physical and geometric constraints. This paper presents a novel technique called Computed Tomographic Fusion (CT-F) which uses three-dimensional Fourier filtering to combine x-ray cone-beam CT reconstructions and ultrasound data in the frequency space. The result is a single image with improved accuracy and quality. CT-F mitigates artifacts while allowing for rapid, accurate characterization of large three-dimensional CT volumes. Finally, using simulations and experiments, we demonstrate artifact reduction and edge contrast improvement in volumetric reconstructions.
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.
A Microwave Time Reversal Algorithm for Imaging Extended Defects in Dielectric Composites
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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.