In-situ Laser ultrasound-based Rayleigh Wave Process Monitoring of DED-AM Metals

C. Bakre, T. Meyer, C. Jamieson, A. R. Nassar, E. W. Reutzel, C. J. Lissenden

Research output: Contribution to journalArticlepeer-review

2 Scopus citations


A laser ultrasound system is integrated into a directed energy deposition additive manufacturing (DED-AM) chamber to use Rayleigh waves for process monitoring in a noncontact layer-by-layer mode. Layers of Ti-6Al-4 V are deposited and then interrogated with ultrasonic Rayleigh waves that are sensitive to flaws and material nonuniformities. The novel integrated material processing and monitoring system is described in detail. Process parameters are intentionally altered to create flaws and anomalies to demonstrate some capabilities of the monitoring system. The generation laser actuates either broadband pulses with a cylindrical lens or narrowband wave packets with a slit mask, which are received in through-transmission mode by a laser interferometer despite the inherent surface roughness. Flaws are detected through comparison to a reference state.

Original languageEnglish (US)
Pages (from-to)218-242
Number of pages25
JournalResearch in Nondestructive Evaluation
Issue number4-5
StatePublished - 2022

All Science Journal Classification (ASJC) codes

  • General Materials Science
  • Condensed Matter Physics
  • Mechanics of Materials
  • Mechanical Engineering


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