In-process ultrasonic inspection of challenging welds and additively manufactured components with complex geometries

This PhD project seeks to improve the ultrasonic imaging of challenging components directly at the point of manufacture. Specifically targeting complex welds and additively manufactured components, this project seeks to extend and adapt thermal and microstructural compensation methods to optimize ultrasonic imaging.
This PhD work will focus on incorporating advanced (PAUT) imaging techniques (FMC-TFM, PWI, PCI, multimodal imaging etc.,) for imaging in-process defects in complex shaped welds and AM components.
Objectives:
- Near real-time mapping of dynamic complex component boundaries from ultrasonic wave parameters and in-process time of flight measurements where a thermal gradient is present and microstructural effects are negligible.
- Mapping of complex and spatially varying microstructures from ultrasonic wave data using models of the thermal gradient and the complex build geometry to constrain the problem.
- Experimental inspection and imaging of complex-shaped welds and additive builds.
- Application of advanced PAUT imaging techniques for inspection of complex configurations of welds and additive manufactured components.
- Study the performances of advanced PAUT methodologies like multi-modal TFM techniques for detection and imaging the full face of different types of defects in welds and AM components.
- Trials and integration of imaging advances within RoboWAAM - The world's first combined WAAM and In-Process NDE Cell.