Possibilities and Limitations of Relevant NDE measurements in support of Quality Assured Additive Manufacturing
Peter Collins | Iowa State University
Approximately 25 years ago, the first commercial metal-based additive manufacturing (AM) systems were finding their way into various research institutions. After a critical first decade when the initial correlations between processing and microstructure were established, AM began to become ‘main-stream’ at various companies. Concurrently, it became obvious that far greater understanding was needed to understand the interrelationships between the physics associated with melting, solidification, defect formation, residual stress, compositional fluctuations, and all aspects of materials state including grain size/morphology/orientation, phase distributions, and defects/damage. There are multiple technical challenges from the materials science perspective, including the need to make measurements with improved spatial (Euclidean, Eulerian) and temporal resolutions. Appropriately, NDE methods are being considered as part of a potential framework to assure the quality of additively manufactured metallic structures. This talk presents the possibilities and limitations of candidate methods for both in-line process monitoring and post-deposition quality assurance. These possibilities and limitations are informed by the relevant length and time scale of the materials state, the additive manufacturing processes, and the NDE methods. Consideration is given to both classical damage/defects (porosity, cracking, lack of fusion), semi-classical defects (residual stress) and materials state attributes that, while being fully dense, are nonetheless weak-links.
About the Speaker
P. C. Collins is a Professor and Entrepreneurial Fellow within the Department of Materials Science and Engineering at Iowa State University and an affiliated faculty in Aerospace Engineering. He received his PhD from The Ohio State University in Materials Science and Engineering. Prior to starting in his first university role, he set up a not-for-profit advanced manufacturing facility embedded in an Army Arsenal. Dr. Collins is actively involved in two NSF Industry/University Cooperative Research Centers, serving as the co-director for the Center for Advanced Non-Ferrous Structural Alloys, and as past director for the Center for Nondestructive Evaluation. His primary research interests involve: the physical metallurgy of advanced non-ferrous materials; advanced characterization techniques including various electron microscopies and emergent spectroscopic methods; quantification of defects and crystal orientation across length scales; combinatorial materials science; advanced materials processing with special interest in additive manufacturing; and the mechanical behavior of non-ferrous materials, including establishing composition-microstructure-property relationships. He has conducted basic and applied research on metal-based additive manufacturing for over 20 years, and most recently has worked to demonstrate new methods to fully characterize the materials state of additively manufactured metallic systems. He has received multiple awards for teaching and his research, and has been actively involved in a variety of professional societies, planning of conferences and symposia, various government panels and working groups, and has >50 publications, >50 invited talks, and multiple US patents.
Innovations in Microwave, Ultrasonic Bondline Inspection, and Portable X-Ray CT
Joseph T. Case | Aerospace Corporation
About the Speaker
Joseph T. Case received his B.S. in physics and electrical engineering with honors in 2003, received his M.S. in electrical engineering in 2006, and received his Ph.D. in electrical engineering in December 2013 from the Missouri University of Science and Technology (Missouri S&T), formerly University of Missouri-Rolla (UMR). He is currently a member of the technical staff at the Aerospace Corporation since January 2014. He performs research in the Physical Sciences Laboratory in the field of nondestructive testing for microwave and millimeter wave, ultrasound, x-ray, thermography, and more (http://www.aerospace.org). Previously, he was a postdoctoral fellow at Missouri S&T in the Applied Microwave Nondestructive Testing Laboratory (amntl) (http://amntl.mst.edu). He started at the amntl in 1999 also serving roles as an Undergraduate and Graduate Research Assistant. He has also worked in the microwave testing lab at NASA Marshall Space Flight Center for intervals between 2004 and 2007. His research interests include real-time imaging systems, digital signal and image processing, multi-modal nondestructive evaluation, free-hand image formation, synthetic aperture radar, three dimensional rendering, and numerical methods. He has over 40 technical publications consisting of journal articles, conference proceedings, and technical reports. He was honored with the 2016 Outstanding Young Engineer Award from IEEE Instrumentation and Measurement Society, 2010 National Science Foundation Graduate Research Fellowship, 2006-2007 MST Chancellor's Fellowship, the 2004 Outstanding Graduate Teaching Assistant at the University of Missouri-Rolla, and the 2002 Norman R. Carson Award as the Outstanding Junior Electrical Engineering Student.
Guided Wave studies for enhanced Acoustic Emission inspection
Joseph Rose |
About the Speaker
Dr. Joseph L. Rose is the Paul Morrow Professor Emeritus in the Engineering Science and Mechanics department at Penn State University who retired from Penn State in 2019. Joe is also the Founder of the company FBS, Inc. dba Guidedwave, a company dedicated to Guided Wave innovation in Nondestructive Evaluation (NDE) and Structural Health Monitoring (SHM).The company plans, designs, builds and maintains guided wave solutions for pipelines, rail, aviation, power generation, manufacturing, civil infrastructure, natural gas and oil facilities, and nuclear and military industries. Dr. Rose has been an international leader in the fields of wave mechanics, ultrasound and ultrasonic guided waves for over four decades He has received many awards for his ground-breaking work in ultrasonic guided waves. Countless plenary and keynote presentations were made at conferences all over the world. He received his Ph.D. in Applied Mechanics from Drexel University in 1970. Joe is currently a fellow of ASNT, ASME, IEEE, and the British Institute for Nondestructive Testing. He is an author of over thirty patents, seven text books, over twenty chapters in various text books, and over 600 publications on ultrasonic NDE, ultrasonic guided waves, wave mechanics, medical ultrasound, adhesive bonding, concrete inspection, pipe and tubing inspection, composite material inspection, ice detection, structural health monitoring, signal processing, and pattern recognition. Recent interest is in Acoustic Emission which fits nicely into Guided Wave studies. Professor Rose also served as a principal advisor to over 60 Ph.D. and 100 M.S. students. A recent textbook is entitled “Ultrasonic Guided Waves in Solid Media,” Cambridge University Press 2014. Joe also published an interesting book, “Seeking the Edge: Thoughts on Wisdom and Success” that was motivated from his storytelling experiences to students all over the world. A few interesting awards includes the following: the 2003 ASME NDE Engineering Division Founder’s Award, the 2007 ASNT Research Council Award for Innovation, the 2011 SPIE Smart Structures/ NDE Lifetime Achievement Award, In recognition of Dr. Rose's sustained contributions to the advancement of Non-destructive Evaluation and Structural Health Monitoring, the 2014 Roy Sharpe Prize, The British Institute for Nondestructive Testing, for lifetime contributions to Ultrasonic Nondestructive Testing, and the 2020 ASNT 50 year Golden Recognition award for ASNT membership and commitment to NDT.