In-line Non-Destructive Evaluation of Additive Layer Manufactured Products
Lead Research Organisation:
University of Nottingham
Department Name: Faculty of Engineering
Abstract
The aim of this project is to develop existing Non-Destructive Evaluation (NDE) techniques towards the inline inspection of Additive Layer Manufactured (ALM) components. The layer by layer nature of the ALM process provides a unique opportunity for surface techniques to be used for the intermediate layer inspection of the component being built. Several of these layer inspections can be used to build up a digital twin of the component being built, which could follow the component across its life cycle. Spatially Resolved Acoustic Spectroscopy has shown great potential towards being a viable option due to its capability to detect and size common surface defects, detect variations to component microstructure and the capability to deal with the surface roughness commonly found in ALM.
Planned Impact
NDE is an important and growing sector, engaging product suppliers and service companies which deliver high impact in terms of safety, asset value maximization and competitive benefit to client industries. NDE is thus an essential enabling technology for end-users across a wide range of sectors, and NDE research is needed to facilitate new engineering designs and materials for both high value manufacturing, as well as for asset management and life extension of existing infrastructure.
Immediate impact will be with the industrial partners where research engineers (REs) will be placed and where many will be ultimately employed. These include the majority of the UK power, oil & gas, nuclear, defence, aerospace and transportation industries. They will benefit through more efficient and safer operation, fewer interruptions to production, reduced wastage, less outage time, and the ability to support new engineering developments. The IDC will build on emerging links with the TSB Catapult centres and with EPSRC manufacturing research centres to maximise the impact of NDE research in these areas. The new IDC will see more RE placements with supply chain companies who will benefit from the growth opportunities afforded by advanced NDE instrumentation and services. The recruitment of high achieving engineers will contribute to rejuvenation of an ageing workforce as well as the need to introduce new engineering skills and capability.
At a national level, improved NDE capability not only underpins key growth areas such as high value manufacturing and energy, but is also crucial to public safety. Ultimately the whole UK economy will benefit through greater efficiency and less down-time, and UK society through increased safety and reduced environmental risk.
Many of the beneficiaries are existing collaborators, who have been engaged regularly through the UK Research Centre in NDE (RCNDE), an industry-university collaboration, whose hub is at Imperial College. 16 major end-user members of RCNDE are represented by NDEvR, the Industrial Partner in a Strategic Partnership with EPSRC. Through NDEvR, RCNDE now has 30 Associate members from the supply chain (many of them SMEs) to stimulate technology transfer. NDEvR has developed a 5,10 & 20 year vision for research needs across a range of market sectors and the IDC programme will be directed at these priorities.
The biggest impact challenge to NDE is addressing the technology transfer gap between research and industrial application, hence the focus here on placing the majority of REs in projects that include technology translation, addressing goals in the 5 and 10 year NDE vision. There is significant longer term impact (matching the NDE 10 and 20 year vision) to be derived from new laboratory research involving quantitative methods as discussed in the case for support, and these too will be addressed by REs.
Impact will be maximised by focused communication and engagement activities between academic partners and industry. These will include 3 plenary meetings and research review annually, typically 3 technology readiness workshops, university visits by industrialists and industrial visits by academics and REs. REs will progressively become part of this engagement process during their training.
The partner universities are already engaged with intermediary organisations such as trainers, and these links will be expanded. Thus individual members play leading roles in professional institutions including the British Institute of NDT, vital for effective dissemination because the majority of the exploiters of NDE research are members.
REs will engage in outreach programmes to raise the profile of engineering in schools and promote the public understanding of NDE, for example through exhibits at science festivals, secondment and publications in the wider media.
Immediate impact will be with the industrial partners where research engineers (REs) will be placed and where many will be ultimately employed. These include the majority of the UK power, oil & gas, nuclear, defence, aerospace and transportation industries. They will benefit through more efficient and safer operation, fewer interruptions to production, reduced wastage, less outage time, and the ability to support new engineering developments. The IDC will build on emerging links with the TSB Catapult centres and with EPSRC manufacturing research centres to maximise the impact of NDE research in these areas. The new IDC will see more RE placements with supply chain companies who will benefit from the growth opportunities afforded by advanced NDE instrumentation and services. The recruitment of high achieving engineers will contribute to rejuvenation of an ageing workforce as well as the need to introduce new engineering skills and capability.
At a national level, improved NDE capability not only underpins key growth areas such as high value manufacturing and energy, but is also crucial to public safety. Ultimately the whole UK economy will benefit through greater efficiency and less down-time, and UK society through increased safety and reduced environmental risk.
Many of the beneficiaries are existing collaborators, who have been engaged regularly through the UK Research Centre in NDE (RCNDE), an industry-university collaboration, whose hub is at Imperial College. 16 major end-user members of RCNDE are represented by NDEvR, the Industrial Partner in a Strategic Partnership with EPSRC. Through NDEvR, RCNDE now has 30 Associate members from the supply chain (many of them SMEs) to stimulate technology transfer. NDEvR has developed a 5,10 & 20 year vision for research needs across a range of market sectors and the IDC programme will be directed at these priorities.
The biggest impact challenge to NDE is addressing the technology transfer gap between research and industrial application, hence the focus here on placing the majority of REs in projects that include technology translation, addressing goals in the 5 and 10 year NDE vision. There is significant longer term impact (matching the NDE 10 and 20 year vision) to be derived from new laboratory research involving quantitative methods as discussed in the case for support, and these too will be addressed by REs.
Impact will be maximised by focused communication and engagement activities between academic partners and industry. These will include 3 plenary meetings and research review annually, typically 3 technology readiness workshops, university visits by industrialists and industrial visits by academics and REs. REs will progressively become part of this engagement process during their training.
The partner universities are already engaged with intermediary organisations such as trainers, and these links will be expanded. Thus individual members play leading roles in professional institutions including the British Institute of NDT, vital for effective dissemination because the majority of the exploiters of NDE research are members.
REs will engage in outreach programmes to raise the profile of engineering in schools and promote the public understanding of NDE, for example through exhibits at science festivals, secondment and publications in the wider media.
| Description | Discovered that the SRAS technique can be used to detect white layer. |
| Exploitation Route | Finding more uses for the SRAS technique that can be used all across the manufacturing industry. |
| Sectors | Aerospace, Defence and Marine,Manufacturing, including Industrial Biotechology |