Development of a phased array ultrasound roller probe for inspection of wire + arc additive manufactured components

The wire + arc additive manufacturing (WAAM) process, which combines an electric as a heat source and metal feedstock is proving to be very effective when producing medium large scale components. non-destructive testing (NDT) of WAAM parts, while they are being produced, provides early intervention opportunities rectify nonconformities perform in-process quality assurance the parts. This attracts significant amount material, time cost savings. Therefore, this paper presents research, development validation high temperature phased array ultrasound (PAUT) roller probe robotically delivered NDT experimental results confirm that PAUT can endure surface temperatures up 350 °C, autonomously deployed via robotic arm detect 1 mm diameter flat-bottom holes located 6 mm, 9 12 deep under unmachined Ti-6Al-4V calibration block.