The University of Bristol researchers have developed a groundbreaking technology that has the potential to revolutionize the manufacturing sector in the U.K. This innovative technology could provide significant commercial advantages in industries by assessing the quality of components with a high level of accuracy.
The key breakthrough in this study is the introduction of ultrasonic array sensors, similar to those used in medical imaging, but with a laser-based approach that eliminates the need for direct contact with the material. This advancement opens up new possibilities for assessing the safety and quality standards of additive manufacturing (3D printing) of metallic components.
The researchers have developed a mathematical model that takes into account the physics of ultrasonic waves propagating through layered metallic materials. This model considers the variability present in each manufactured component and provides a formula for designing the ultrasonic laser equipment based on the specific material properties. By optimizing the design parameters, the sensor can produce accurate information to assess the mechanical integrity of the components.
The potential of this technology lies in its ability to accelerate the design and deployment of solutions for manufacturing safety critical components. By partnering with industry collaborators, the researchers aim to create bespoke imaging algorithms that generate tomographic images of component interiors. This data can then be used to assess the quality of components in a non-destructive manner, revolutionizing the manufacturing process and leading to new designs that maximize the benefits of 3D printing.
Moving forward, the research team plans to collaborate with experimental partners to deploy laser-based ultrasonic arrays in controlled additive manufacturing environments. By maximizing the information content in the sensor data, they aim to provide a means of assessing mechanical integrity at the manufacturing stage. This breakthrough could open up new opportunities for industries, particularly in sectors like aerospace, where safety critical components are essential.
The development of laser-based ultrasonic arrays for assessing component quality represents a significant advancement in manufacturing technology. By overcoming the challenge of assessing mechanical integrity in safety critical components, this technology has the potential to provide substantial commercial advantages to the U.K. industry. The future of manufacturing looks promising with this innovative sensing technology at its forefront.