Damage detection in load-bearing additive manufacturing components through use of high-frequency ultrasonic waves

使用高频超声波检测承重增材制造部件的损伤

• 批准号: 542310-2019
• 负责人: VarvaniFarahani, Ahmad
• 金额: $ 1.82万
• 依托单位: Ryerson University
• 依托单位国家: 加拿大
• 项目类别: Engage Grants Program
• 财政年份: 2019
• 资助国家: 加拿大
• 起止时间: 2019-01-01 至 2020-12-31
• 项目状态: 已结题
• 来源: https://www.nserc-crsng.gc.ca/ase-oro/Details-Detailles_eng.asp?id=680418
• 关键词: Damage; detection; load; bearing; additive

Damage detection and health monitoring of load-bearing components have been always prime concern for designers and manufacturers. One of modern processes used for manufacturing of metallic and non-metallic parts is additive manufacturing (AM), also referred to as three-dimensional printing or rapid prototyping. In an additive manufacturing process, a computer program directs a scanner to deposit the material precisely at desired spots to build up the final product layer by layer. This makes it possible to produce objects with complex geometries relatively easier and at an affordable cost. The material could be metal, plastic or ceramic which is melted by an energy source such as laser beam, arc, electron beam or ultrasound. The absence of defects in AM components is critically important, particularly if implanted in human body as a prosthesis. For prostheses, such as knee joint, the product must be defect-free. The detection and monitoring of defects growing under repeated loads necessitates to employ advanced non-destructive testing (NDT) techniques, which do not damage the serviceability of the product. In this project, a unique phased array ultrasonic testing (PAUT) method will be employed. The PAUT has been in use for several years by industries with limited frequency of maximum 10 MHz. This level of frequency is not high enough to assure detection of very small defects/cracks in load-bearing AM products. The present study offers the use of phased array ultrasonic testing method with higher frequencies, as high as 50 MHz, to detect and monitor AM manufactured prostheses components under repeated loads. The method enables defect detection and cracking of few microns over early stages of loading addressing shortcomings of other NDT techniques. The outcome of this project upon completion is to safely manufacture additive components, to minimize damage in the manufactured parts, and to promote risk-free and reliable biomedical products including knee joint prosthesis in service. It is also expected that the mutual collaboration between Ryerson University and FUJIFILM VisualSonics Inc. expands over longer terms through this NSERC engage proposal.

承载部件的损伤检测和健康监测一直是设计者和制造商最关心的问题。用于制造金属和非金属零件的现代工艺之一是增材制造 (AM)，也称为三维打印或快速原型制作。在增材制造过程中，计算机程序指示扫描仪将材料精确地沉积在所需位置，以逐层构建最终产品。这使得生产具有复杂几何形状的物体变得相对容易并且成本低廉。该材料可以是由激光束、电弧、电子束或超声波等能量源熔化的金属、塑料或陶瓷。增材制造组件的无缺陷至关重要，特别是作为假体植入人体时。对于膝关节等假肢，产品必须没有缺陷。对重复负载下不断增长的缺陷进行检测和监控需要采用先进的无损检测 (NDT) 技术，该技术不会损害产品的适用性。在该项目中，将采用独特的相控阵超声测试（PAUT）方法。 PAUT 已被频率限制为最大 10 MHz 的行业使用多年。此频率水平不够高，无法确保检测承重增材制造产品中非常小的缺陷/裂纹。本研究提供了使用更高频率（高达 50 MHz）的相控阵超声测试方法来检测和监测重复负载下的增材制造假肢部件。该方法能够在加载的早期阶段检测到几微米的缺陷和裂纹，解决了其他无损检测技术的缺点。该项目完成后的成果是安全地制造增材部件，最大限度地减少制造部件的损坏，并推广无风险且可靠的生物医学产品，包括投入使用的膝关节假体。预计瑞尔森大学和 FUJIFILM VisualSonics Inc. 之间的相互合作将通过这项 NSERC 参与提案得到长期扩展。