Abstract: Compared with traditional formative or subtractive manufacturing technology, metal 3D printing, as an additive manufacturing technology, enables free-form fabrication of complex structural components, and has broad application prospects in the industrial fields of automobile, nuc-lear power, aerospace, etc. However, due to the rapid and repeated melting and solidification, and complex heat transfer and phase transition during the 3D-printing process, the quality of 3D-printed parts cannot be guaranteed. In fact, lack of effective quality monitoring methods is a technical bottleneck restricting the promotion and application of metal 3D printing technology. Among many non-destructive testing technologies, the ultrasonic testing technology has shown great potential in the 3D printing quality monitoring and control due to its high sensitivity, strong penetrability and wide applicability for materials. However, because of the particularity of 3D printing forming process, the metallurgical characteristics of the 3D-printed parts are obviously different from those of traditional castings and for-gings. Specifically, the microstructure anisotropy is obvious, and defects such as pores, non-fusion, cracks and so on are easy to appear. The presence of large residual stress is easy to cause the deformation of curl distortion. This brings great challenges to the traditional ultrasonic testing technology. Meanwhile, 3D-printed parts have obvious personalized characteristics. Complex structures of hollow and thin wall may cause problems such as poor accessibility of ultrasonic signals and large detection blind areas. On the other hand, metal 3D printing, as a one-step forming technology, the on-line real-time detection of the forming process is particularly important. Nevertheless, the complex environment conditions in the 3D printing forming cavity, such as high temperature, dust and strong light scattering, affect the performance and stability of the ultrasonic inspection system and greatly increase the difficulty of inspection. Therefore, targeted research on ultrasonic offline and online detection has become a research hotspot in recent years. Recently, with respect to the ultrasonic testing and evaluation of metallurgical characteristics of 3D-printed metal parts, researchers have found correlation between microstructure anisotropy and ultrasonic propagation characteristics, yet there is insufficient research about quantitative analysis of microstructure grain size. The localization and size evaluation of artificial implantable defects are mainly studied, but research on the detection of defects naturally formed in the 3D-printing process is still insufficient. Ultrasonic characterization of surface residual stress has been stu-died, but there are few research reports on ultrasonic inspection of subsurface residual stress which may be more dangerous. Most of the research work on online ultrasonic monitoring of printing process is still at experimental stage. For further engineering application, there are still research difficulties such as large surface roughness, complex environment in forming cavity, closed-loop process control based on online detection information, etc. In this paper, the necessity of quality control of metal 3D printing process is described firstly. Secondly, nondestructive testing technologies commonly used in 3D printing are summarized. Then, this paper focuses on the application status of ultrasonic testing technology in metal 3D printing, including the research progress and challenges of offline/online testing of metallurgical characteristics such as microstructures, defects, and residual stresses. Finally, the application of ultrasonic detection technology in metal 3D printing is summarized and prospected.
许万卫, 白雪, 马健, 刘帅. 超声检测在金属3D打印中的应用研究进展[J]. 材料导报, 2022, 36(18): 21030217-10.
XU Wanwei, BAI Xue, MA Jian, LIU Shuai. Research Progress of Ultrasonic Testing in Metal 3D Printing. Materials Reports, 2022, 36(18): 21030217-10.
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