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Nondestructive Inspection of Directed Energy Deposited Components Using Scanning Acoustic Microscopy with Metalworking Fluids

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Abstract

Directed energy deposition (DED) is a metal additive manufacturing (AM) technique that can create new products or repair damaged ones by depositing molten metal powders with a high-power source. However, defects such as spherical gas pores or irregularly shaped lack-of-fusion pores can occur during the DED process, and it is necessary to evaluate those defects to ensure the stability of the DED process and to improve the quality of DED products. This work studied scanning acoustic microscopy (SAM) using metalworking fluids—cutting oil and anti-rust oil—as coupling media to characterize the internal and interfacial defects in DED components. Water as generally used in SAM was also tested as a reference and its results were compared with those of the fluids. First, the physical properties of each coupling medium were measured, and then its acoustic attenuation coefficient was calculated based on Stokes’ law of sound attenuation. Second, the capability for defect detection was evaluated using drilled holes in an aluminum specimen, using each coupling medium. Finally, the internal and interfacial porosities of the DED specimens were characterized using SAM. The experimental results showed that the coupling performance of the cutting oil was similar to that of water, while that of the anti-rust oil was clearly degraded because that oil caused high attenuation of ultrasonic waves. These comparison results suggest that it would be better to inspect metal DED components using SAM with cutting oil.

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Acknowledgements

This paper was supported by the Korea Institute of Machinery & Materials grant funded by the Korean government (MSIT) (NK230I), research funds for newly appointed professors of Jeonbuk National University in 2020, and National Research Foundation of Korea funded by the Korean government (MSIT) (2021M2E6A108469).

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Authors and Affiliations

  1. Department of Mechanical Engineering, Stanford University, Stanford, CA, 94305, USA

    Seong-Hyun Park

  2. LANL-JBNU Engineering Institute-Korea, and Department of Flexible and Printable Electronics, Jeonbuk National University, Jeonju-Si, Jeollabuk-Do, 54896, Republic of Korea

    Sungho Choi

  3. School of Mechanical Engineering, Hanyang University, 222 Wangsimni-Ro, Seongdong-Gu, Seoul, 04763, Republic of Korea

    Kyung-Young Jhang

  4. Department of 3D Printing, Korea Institute of Machinery & Materials, Daejeon, 34103, Republic of Korea

    Taeho Ha

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  1. Seong-Hyun Park
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Correspondence to Sungho Choi or Kyung-Young Jhang.

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Park, SH., Choi, S., Jhang, KY. et al. Nondestructive Inspection of Directed Energy Deposited Components Using Scanning Acoustic Microscopy with Metalworking Fluids. Int. J. Precis. Eng. Manuf. 24, 2099–2112 (2023). https://doi.org/10.1007/s12541-023-00854-z

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