Optimization of an Additive Manufacturing Process Using Ultrasound

Additive Manufacturing is used for printing parts with high precision and complex geometries, but achieving consistent material properties and avoiding defects is a challenge. This paper presents the use of ultrasound technology as a non-destructive method to optimize the additive manufacturing process. A factorial design is used to print 18 samples using the key process parameters such as Power, Speed, and Hatch Distance. The ultrasound measurements are carried out using a 7.5 MHz focused transducer to capture within-sample variation. The manufacturing parameters and ultrasound variation metric is converted to a response surface model which is then used to identify optimal manufacturing conditions that can help minimize process induced variation and get a consistent microstructure and achieve consistent mechanical properties.