Skip to main content
SpringerLink
Log in

Ultrasonic Measurement of Microstructural Anisotropy in a Ni-Based Superalloy Fabricated by Direct Laser Deposition

  • Published:
Journal of Nondestructive Evaluation Aims and scope Submit manuscript

Abstract

In this article, the anisotropic microstructure of a nickel IN718 sample fabricated on a forged nickel alloy base plate by the Additive Manufacturing (AM) method using the Direct Laser Deposition (DLD) technique was characterized by the mode-converted (Longitudinal to Transverse, L-T) ultrasonic scattering. The L-T ultrasonic measurements were conducted using two same focused transducers in a pitch-catch configuration on both forged and AM regions in two perpendicular directions. The ultrasonic scattered signal was converted to the two-dimensional scalogram through the Continuous Wavelet Transform (CWT). The energy distribution of ultrasonic scattering over the whole traveling path was obtained in the Time-Frequency (TF) domain. The apparent integrated scatter (AIS) was calculated to represent scattering energy by selecting the time window over the focal zone and the right frequency range. The AIS ratio of \({L}_{z}-{T}_{y}\)/\({L}_{z}-{T}_{x}\) measured in two perpendicular directions was used to quantify the microstructural anisotropy at each measurement spot. Then the variation of the microstructural anisotropy can be imaged over the whole sample, from which it can be seen that the microstructural anisotropy increased progressively towards the interface between the AM region and the forged base plate, and reached the maximum near the interface. The dependence of the characterization of microstructural anisotropy on the selection of the time window was also investigated by choosing several different time windows around the focal zone. The results show that the characterization of microstructural anisotropy was barely influenced, a result which indicates the measurement stability of this method. The mode-converted diffuse ultrasonic scattering technique demonstrates a strong sensitivity to anisotropic microstructure, an outcome that can be applicable for quality control during additive manufacturing.

This is a preview of subscription content, log in via an institution to check access.

Access this article

Log in via an institution

Price excludes VAT (USA)
Tax calculation will be finalised during checkout.

Instant access to the full article PDF.

Institutional subscriptions

Fig. 1
Fig. 2
Fig. 3
Fig. 4
Fig. 5
Fig. 6
Fig. 7
Fig. 8

Similar content being viewed by others

Data Availability

Not applicable for this section.

References

  1. Frazier, W.E.: Metal additive manufacturing: a review. J. Mater. Eng. Perform 23(6), 1917–1928 (2014)

    Article  Google Scholar 

  2. Xiang, Y., Zhang, S., Wei, Z., Li, J., Wei, P., Chen, Z., Yang, L., Jiang, L.: Forming and defect analysis for single track scanning in selective laser melting of Ti6 Al 4V. Appl. Phys. A. 124(10), 685 (2018)

    Article  Google Scholar 

  3. Olakanmi, E.O., Cochrane, R.F., Dalgarno, K.W.: A review on selective laser sintering/melting (SLS/SLM) of aluminium alloy powders: processing, microstructure, and properties. Prog Mater. Sci 74, 401–477 (2015)

    Article  Google Scholar 

  4. Thompson, A., Maskery, I., Leach, R.K.: X-ray computed tomography for additive manufacturing: a review. Meas. Sci. Technol 27(7), 072001 (2016)

    Article  Google Scholar 

  5. Pejryd, L., Karlsson, P., Hallgren, S., Kahlin, M.: Non-destructive evaluation of internal defects in additive manufactured aluminium, In European Congress and Exhibition on Powder Metallurgy. European PM Conference Proceedings: The European Powder Metallurgy Association, pp. 1–7. (2016)

  6. Lu, Q.Y., Wong, C.H.: Additive manufacturing process monitoring and control by non-destructive testing techniques: challenges and in-process monitoring. Virtual Phys. Prototyping 13(2), 39–48 (2018)

    Article  Google Scholar 

  7. Honarvar, F., Varvani-Farahani, A.: A review of ultrasonic testing applications in additive manufacturing: defect evaluation, material characterization, and process control. Ultrasonics 108, 106227 (2020)

    Article  Google Scholar 

  8. Lopez, A., Bacelar, R., Pires, I., Santos, T.G., Sousa, J.P., Quintino, L.: Non-destructive testing application of radiography and ultrasound for wire and arc additive manufacturing. Additive Manuf. 21, 298–306 (2018)

    Article  Google Scholar 

  9. Lopez, A.B., Santos, J., Sousa, J.P., Santos, T.G., Quintino, L.: Phased array ultrasonic inspection of metal additive manufacturing parts. J. Nondestr. Eval 38, 62 (2019)

    Article  Google Scholar 

  10. Allam, A., Alfahmi, O., Patel, H., Sugino, C., Harding, M., Ruzzene, M., Erturk, A.: Ultrasonic testing of thick and thin Inconel 625 alloys manufactured by laser powder bed fusion. Ultrasonics. 125, 106780 (2022)

    Article  Google Scholar 

  11. Javadi, Y., MacLeod, C.N., Pierce, S.G., Gachagan, A., Lines, D., Mineo, C., Ding, J., Williams, S., Vasilev, M., Mohseni, E., Su, R.: Ultrasonic phased array inspection of a wire + arc additive manufactured (WAAM) sample with intentionally embedded defects. Additive Manuf. 29, 100806 (2019)

    Article  Google Scholar 

  12. Ma, Y., Hu, Z., Tang, Y., Ma, S., Chu, Y., Li, X., Luo, W., Guo, L., Zeng, X., Lu, Y.: Laser opto-ultrasonic dual detection for simultaneous compositional, structural, and stress analyses for wire + arc additive manufacturing. Additive Manuf. 31, 100956 (2020)

    Article  Google Scholar 

  13. Sol, T., Hayun, S., Noiman, D., Tiferet, E., Yeheskel, O., Tevet, O.: Nondestructive ultrasonic evaluation of additively manufactured AlSi 10Mg samples. Additive Manuf. 22, 700–707 (2018)

    Article  Google Scholar 

  14. Kube, C.M., Shu, Y., Lew, A.J., Galles, D.: Real-time characterization of laser-generated melt pools using ultrasound. Mater. Eval. 76, 525–534 (2018)

    Google Scholar 

  15. Rose, J.H.: Ultrasonic backscatter from microstructure. In: Thompson, D.O., Chimenti, D.E. (eds.) Review of Progress in QNDE, vol. 11, pp. 1677–1684. Plenum, New York (1992)

    Google Scholar 

  16. Han, Y.K., Thompson, R.B.: Ultrasonic backscattering in duplex microstructures: theory and application to titanium alloy. Metall. Mater. Trans. A 28A, 91–104 (1997)

    Article  Google Scholar 

  17. Du, H., Lonsdale, C., Oliver, J., Wilson, B.M., Turner, J.A.: Evaluation of railroad Wheel Steel with Lamellar duplex microstructures using diffuse Ultrasonic Backscatter. J. Nondestruct. Eval. 32, 331–340 (2013)

    Article  Google Scholar 

  18. Du, H., Lonsdale, C., Oliver, J., Wilson, B.M., Turner, J.A.: Measurement of quench depth in railroad wheels by diffuse ultrasonic backscatter. J. Nondestruct Eval. 33, 104–110 (2014)

    Google Scholar 

  19. Du, H., Turner, J.A.: Dependence of diffuse ultrasonic backscatter on residual stress in 1080 steel. Ultrasonics. 67, 65–69 (2016)

    Article  Google Scholar 

  20. Lobkis, O.I., Yang, L., Li, J., Rokhlin, S.I.: Ultrasonic backscattering in polycrystals with elongated single phase and duplex microstructures. Ultrasonics. 52, 694–705 (2012)

    Article  Google Scholar 

  21. Yang, L., Li, J., Lobkis, O.I., Rokhlin, S.I.: Ultrasonic propagation and scattering in duplex microstructures with application to titanium alloys. J. Nondestruct. Eval. 31, 270–283 (1991)

    Article  Google Scholar 

  22. Hu, P., Kube, C.M., Koester, L.W., Turner, J.A.: Mode-converted diffuse ultrasonic backscatter. J. Acoust. Soc. Am. 134(2), 982–990 (2013)

    Article  Google Scholar 

  23. Arguelles, A.P., Kube, C.M., Hu, P., Turner, J.A.: Mode-converted ultrasonic scattering in polycrystals with elongated grains. J. Acoust. Soc. Am. 140(3), 1570–1580 (2016)

    Article  Google Scholar 

  24. Du, H., Turner, J.A., Hu, P.: Characterization of microstructural anisotropy in pearlitic steel with mode-converted ultrasonic scattering. NDT and E. Int. 102, 189–193 (2019)

    Article  Google Scholar 

  25. Du, H.: Characterization of microstructural anisotropy using the mode-converted ultrasonic scattering in titanium alloy. Ultrasonics. 119, 106633 (2022)

    Article  Google Scholar 

  26. Chen, Y., Zhang, X., Parvez, M.M., Liou, F.: A review on metallic alloys fabrication using elemental powder blends by laser powder directed energy deposition process. Materials. 13(16), 3562 (2020)

    Article  Google Scholar 

  27. Jinoop, A.N., Paul, C.P., Bindra, K.S.: Laser-assisted directed energy deposition of nickel super alloys: a review. Proc. Institution Mech. Eng. Part L J. Mater. Design. Appl. 233(11), 2376–2400 (2019)

    Google Scholar 

  28. Liu, C., Ta, D., Fujita, F., Hachiken, T., Matsukawa, M., Mizuno, K., Wang, W.: The relationship between ultrasonic backscatter and trabecular anisotropic microstructure in cancellous bone. J. Appl. Phys. 115, 064906 (2014)

    Article  Google Scholar 

  29. Panetta, P.D., Du, H., Hassan, W. Characterization of additive manufactured IN718 using ultrasonic measurements, [Conference Presentation], TMS 2017 Conference, Feb. 26–Mar.2, 2017 San Diego, California, USA. https://tms.org/meetings/annual-17/AM17home.aspx

Download references

Acknowledgements

The authors would like to thanks Dr. Paul Panetta for providing the sample and helping with the data acquisition.

Funding

This work has been funded by the National Key Research and Development Program of China with the granting number of 2022YFB4602402.

Author information

Authors and Affiliations

  1. State Key Laboratory of Robotics, Shenyang Institute of Automation, Chinese Academy of Sciences, Shenyang, 110016, China

    Hualong Du & Di Yao

  2. Institutes for Robotics and Intelligent Manufacturing, Chinese Academy of Sciences, Shenyang, 110169, China

    Hualong Du & Di Yao

Authors
  1. Hualong Du
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. Di Yao
    View author publications

    You can also search for this author in PubMed Google Scholar

Contributions

Hualong Du wrote the main manuscript text, and Di Yao prepared all figures. All authors reviewed the manuscript.

Corresponding author

Correspondence to Hualong Du.

Ethics declarations

Ethics Approval and Consent to Participate

Not applicable for this section.

Consent for Publication

The authors confirm that the results/data/figures in this manuscript have not been published elsewhere, nor are they under consideration (from you or one of your Contributing Authors) by another publisher.

Competing interests

The authors declare no competing interests.

Additional information

Publisher’s Note

Springer Nature remains neutral with regard to jurisdictional claims in published maps and institutional affiliations.

Rights and permissions

Springer Nature or its licensor (e.g. a society or other partner) holds exclusive rights to this article under a publishing agreement with the author(s) or other rightsholder(s); author self-archiving of the accepted manuscript version of this article is solely governed by the terms of such publishing agreement and applicable law.

Reprints and permissions

About this article

Check for updates. Verify currency and authenticity via CrossMark

Cite this article

Du, H., Yao, D. Ultrasonic Measurement of Microstructural Anisotropy in a Ni-Based Superalloy Fabricated by Direct Laser Deposition. J Nondestruct Eval 42, 60 (2023). https://doi.org/10.1007/s10921-023-00971-9

Download citation

  • Received:

  • Accepted:

  • Published:

  • DOI: https://doi.org/10.1007/s10921-023-00971-9

Keywords

Search

Navigation