Detecting Thermal Crack Growth on a Large Additive Manufactured Structure using Acoustic Emission

Ryan Spencer; Miguel González Núñez; Hossain Saboonchi; Valery Godinez-Azcuaga; Uday Vaidya; Vlastimil Kunc; Ahmed Arabi Hassen

doi:10.1117/12.2615094

Detecting Thermal Crack Growth on a Large Additive Manufactured Structure using Acoustic Emission

Ryan Spencer
, Miguel González Núñez
, Hossain Saboonchi
, Valery Godinez-Azcuaga
, Uday Vaidya
, Vlastimil Kunc
, Ahmed Arabi Hassen

Research output: Chapter in Book/Report/Conference proceeding › Conference contribution › peer-review

Abstract

Large format additive manufacturing (LFAM) proved to have a great potential to become an adjacent technology to traditional manufacturing methods. One of the sectors LFAM is targeting is rapid tool/mold development for composites. This includes large mold structures used for high-temperature molding techniques (in-oven or autoclave). Although, these large printed structures (reaching hundreds of pounds) develop thermal-residual stress during cool-down and can eventually crack, turning the structure into waste. Acoustic emission (AE), a passive non-intrusive global nondestructive evaluation (NDE) technique, was used to monitor crack growth and can provide the right tools that can be used for feedback loop for corrective action. This research performs thermal testing on a large AM mold with preexisting cracks, in an attempt to monitor crack growth using AE. AE was able to detect, identify and locate the crack source by means of acoustic features, waveform characteristics, spectrum analysis, and difference in arrival times.

Original language	English
Title of host publication	Nondestructive Characterization and Monitoring of Advanced Materials, Aerospace, Civil Infrastructure, and Transportation XVI
Editors	H. Felix Wu, Andrew L. Gyekenyesi, Peter J. Shull, Tzuyang Yu
Publisher	SPIE
ISBN (Electronic)	9781510649699
DOIs	https://doi.org/10.1117/12.2615094
State	Published - 2022
Event	Nondestructive Characterization and Monitoring of Advanced Materials, Aerospace, Civil Infrastructure, and Transportation XVI 2022 - Virtual, Online Duration: Apr 4 2022 → Apr 10 2022

Publication series

Name	Proceedings of SPIE - The International Society for Optical Engineering
Volume	12047
ISSN (Print)	0277-786X
ISSN (Electronic)	1996-756X

Conference

Conference	Nondestructive Characterization and Monitoring of Advanced Materials, Aerospace, Civil Infrastructure, and Transportation XVI 2022
City	Virtual, Online
Period	04/4/22 → 04/10/22

Funding

Research sponsored by the U.S. Department of Energy, Office of Energy Efficiency and Renewable Energy, Advanced Manufacturing Office, under contract DE-AC05-00OR22725 with UT-Battelle, LLC. Part of this work was funded in part by the Office of Energy Efficiency and Renewable Energy (EERE), U.S. Department of Energy, under Award Number DE-EE0006926. We gratefully acknowledge the Institute of Advanced Composites Manufacturing Innovation (IACMI) and the Manufacturing Demonstration Facility (MDF), Oakridge National Laboratory (ORNL), TN, USA for financial and facilities support. This manuscript has been authored by UT-Battelle, LLC, under contract DE-AC05-00OR22725 with the US Department of Energy (DOE). The published acknowledges the US government license to provide public access under the DOE Public Access Plan (http://energy.gov/downloads/doe-public-access-plan)

Keywords

Acoustic Emission
Large Format Additive Manufacturing
Nondestructive Evaluation

Access to Document

10.1117/12.2615094

Cite this

Spencer, R., Núñez, M. G., Saboonchi, H., Godinez-Azcuaga, V., Vaidya, U., Kunc, V., & Hassen, A. A. (2022). Detecting Thermal Crack Growth on a Large Additive Manufactured Structure using Acoustic Emission. In H. F. Wu, A. L. Gyekenyesi, P. J. Shull, & T. Yu (Eds.), Nondestructive Characterization and Monitoring of Advanced Materials, Aerospace, Civil Infrastructure, and Transportation XVI Article 120470W (Proceedings of SPIE - The International Society for Optical Engineering; Vol. 12047). SPIE. https://doi.org/10.1117/12.2615094

Spencer, Ryan ; Núñez, Miguel González ; Saboonchi, Hossain et al. / Detecting Thermal Crack Growth on a Large Additive Manufactured Structure using Acoustic Emission. Nondestructive Characterization and Monitoring of Advanced Materials, Aerospace, Civil Infrastructure, and Transportation XVI. editor / H. Felix Wu ; Andrew L. Gyekenyesi ; Peter J. Shull ; Tzuyang Yu. SPIE, 2022. (Proceedings of SPIE - The International Society for Optical Engineering).

@inproceedings{40410bfcc9e843c198f6100c081940a6,

title = "Detecting Thermal Crack Growth on a Large Additive Manufactured Structure using Acoustic Emission",

abstract = "Large format additive manufacturing (LFAM) proved to have a great potential to become an adjacent technology to traditional manufacturing methods. One of the sectors LFAM is targeting is rapid tool/mold development for composites. This includes large mold structures used for high-temperature molding techniques (in-oven or autoclave). Although, these large printed structures (reaching hundreds of pounds) develop thermal-residual stress during cool-down and can eventually crack, turning the structure into waste. Acoustic emission (AE), a passive non-intrusive global nondestructive evaluation (NDE) technique, was used to monitor crack growth and can provide the right tools that can be used for feedback loop for corrective action. This research performs thermal testing on a large AM mold with preexisting cracks, in an attempt to monitor crack growth using AE. AE was able to detect, identify and locate the crack source by means of acoustic features, waveform characteristics, spectrum analysis, and difference in arrival times.",

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Spencer, R, Núñez, MG, Saboonchi, H, Godinez-Azcuaga, V, Vaidya, U, Kunc, V & Hassen, AA 2022, Detecting Thermal Crack Growth on a Large Additive Manufactured Structure using Acoustic Emission. in HF Wu, AL Gyekenyesi, PJ Shull & T Yu (eds), Nondestructive Characterization and Monitoring of Advanced Materials, Aerospace, Civil Infrastructure, and Transportation XVI., 120470W, Proceedings of SPIE - The International Society for Optical Engineering, vol. 12047, SPIE, Nondestructive Characterization and Monitoring of Advanced Materials, Aerospace, Civil Infrastructure, and Transportation XVI 2022, Virtual, Online, 04/4/22. https://doi.org/10.1117/12.2615094

Detecting Thermal Crack Growth on a Large Additive Manufactured Structure using Acoustic Emission. / Spencer, Ryan; Núñez, Miguel González; Saboonchi, Hossain et al.
Nondestructive Characterization and Monitoring of Advanced Materials, Aerospace, Civil Infrastructure, and Transportation XVI. ed. / H. Felix Wu; Andrew L. Gyekenyesi; Peter J. Shull; Tzuyang Yu. SPIE, 2022. 120470W (Proceedings of SPIE - The International Society for Optical Engineering; Vol. 12047).

Research output: Chapter in Book/Report/Conference proceeding › Conference contribution › peer-review

TY - GEN

T1 - Detecting Thermal Crack Growth on a Large Additive Manufactured Structure using Acoustic Emission

AU - Spencer, Ryan

AU - Núñez, Miguel González

AU - Saboonchi, Hossain

AU - Godinez-Azcuaga, Valery

AU - Vaidya, Uday

AU - Kunc, Vlastimil

AU - Hassen, Ahmed Arabi

PY - 2022

Y1 - 2022

N2 - Large format additive manufacturing (LFAM) proved to have a great potential to become an adjacent technology to traditional manufacturing methods. One of the sectors LFAM is targeting is rapid tool/mold development for composites. This includes large mold structures used for high-temperature molding techniques (in-oven or autoclave). Although, these large printed structures (reaching hundreds of pounds) develop thermal-residual stress during cool-down and can eventually crack, turning the structure into waste. Acoustic emission (AE), a passive non-intrusive global nondestructive evaluation (NDE) technique, was used to monitor crack growth and can provide the right tools that can be used for feedback loop for corrective action. This research performs thermal testing on a large AM mold with preexisting cracks, in an attempt to monitor crack growth using AE. AE was able to detect, identify and locate the crack source by means of acoustic features, waveform characteristics, spectrum analysis, and difference in arrival times.

AB - Large format additive manufacturing (LFAM) proved to have a great potential to become an adjacent technology to traditional manufacturing methods. One of the sectors LFAM is targeting is rapid tool/mold development for composites. This includes large mold structures used for high-temperature molding techniques (in-oven or autoclave). Although, these large printed structures (reaching hundreds of pounds) develop thermal-residual stress during cool-down and can eventually crack, turning the structure into waste. Acoustic emission (AE), a passive non-intrusive global nondestructive evaluation (NDE) technique, was used to monitor crack growth and can provide the right tools that can be used for feedback loop for corrective action. This research performs thermal testing on a large AM mold with preexisting cracks, in an attempt to monitor crack growth using AE. AE was able to detect, identify and locate the crack source by means of acoustic features, waveform characteristics, spectrum analysis, and difference in arrival times.

KW - Acoustic Emission

KW - Large Format Additive Manufacturing

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M3 - Conference contribution

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A2 - Yu, Tzuyang

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Y2 - 4 April 2022 through 10 April 2022

ER -

Spencer R, Núñez MG, Saboonchi H, Godinez-Azcuaga V, Vaidya U, Kunc V et al. Detecting Thermal Crack Growth on a Large Additive Manufactured Structure using Acoustic Emission. In Wu HF, Gyekenyesi AL, Shull PJ, Yu T, editors, Nondestructive Characterization and Monitoring of Advanced Materials, Aerospace, Civil Infrastructure, and Transportation XVI. SPIE. 2022. 120470W. (Proceedings of SPIE - The International Society for Optical Engineering). doi: 10.1117/12.2615094

Detecting Thermal Crack Growth on a Large Additive Manufactured Structure using Acoustic Emission

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