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Resonant Ultrasonic Testing can Quantitatively Assess the Microscopic Porosity of Complex-Shaped Additively Manufactured AlSi10Mg Components

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Abstract

The utility of resonant ultrasonic testing for quality control of complex-shaped additively manufactured (AM) components in terms of porosity variations is investigated. A fully non-contact test setup is used to investigate differences in the volumetric porosity between AM AlSi10Mg samples. A set of 96 samples with programmatically induced pores varying in nominal total porosity between 0% and 2% is tested: one half of the samples are prismatic, and the other half have a complex internal Triply Periodic Minimal Surface (TPMS) structure. In addition, a subset of the samples is scanned using X-ray micro-computed tomography (µ-CT). It is found that the resonance frequency corresponding to the 1st compressional mode can predict the total nominal porosity even in TPMS samples. From statistical analysis, the smallest detectable porosity difference is found to be 0.25% for the prismatic samples and 0.5% for the TPMS samples. The experimental results agree well with the predictions of finite element (FE) simulations and analytical models. However, X-ray µ-CT appears to underestimate the porosity, possibly due to its inability to resolve the small pores. Our findings suggest that resonant ultrasonic testing can quantitatively assess the total porosity of AM parts having complex geometries.

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Data Availability

The dataset generated during and/or analyzed during the current study will be available upon request.

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Acknowledgements

The imaging of the samples was performed at the Center for Quantitative Imaging (CQI) at the Pennsylvania State University. The co-authors would like to thank the CQI’s researchers Andrew T. Ross, America Campillo, and Dr. Mina Odette for their assistance in the acquisition of X-ray scans and the porosity analysis performed in AVIZO.

Funding

This project was supported by two seed grants awarded to Dr. Parisa Shokouhi from the Institute for Computational and Data Sciences (ICDS) and the Applied Research Laboratory (ARL-COE) at the Pennsylvania State University.

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Authors and Affiliations

  1. Department of Engineering Science and Mechanics, The Pennsylvania State University, University Park, PA, 16802, USA

    Michail Skiadopoulos, Evan P. Bozek & Parisa Shokouhi

  2. Department of Mechanical Engineering, The Pennsylvania State University, University Park, PA, 16802, USA

    Dominic J. Prato

  3. Applied Research Laboratory, The Pennsylvania State University, University Park, PA, 16802, USA

    Corey J. Dickman, Edward W. Reutzel & David J. Corbin

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Contributions

M.S.: Data collection, Data analysis, Software, Preparation, Writing – original draft, Writing – review & Editing. D.J.P.: Data collection. E.P.B.: Methodology, Data collection, Data analysis, Review & Editing. C.D. & E.W.R. & D.J.C.: Sample preparation, Writing – review & Editing.P.S.: Supervision, Investigation, Funding acquisition, Conceptualization, Writing – original draft, Writing – review & Editing.

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Correspondence to Parisa Shokouhi.

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Skiadopoulos, M., Prato, D.J., Bozek, E.P. et al. Resonant Ultrasonic Testing can Quantitatively Assess the Microscopic Porosity of Complex-Shaped Additively Manufactured AlSi10Mg Components. J Nondestruct Eval 43, 41 (2024). https://doi.org/10.1007/s10921-024-01064-x

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