Due to its ability to manufacture a single, complex part that either (1) could not have been built with traditional manufacturing or (2) would require the assembly of several sub-components, the use of Metal Additive Manufacturing (MAM) has increased over 300% in just the last 5 years1,2. Even with the advancements in the technology of Metal Additive Manufacturing, the final as-built mechanical properties continue to possess variability that make it difficult for designers and engineers to utilize them effectively, especially on mission critical parts. The final material properties of an MAM part are process and operator-dependent and the MAM process is more complex than traditional metal manufacturing techniques. The ability to non-destructively validate the quality of an MAM part is critical as the utilization of metal these parts increases. This paper describes ongoing research that focuses on techniques that can predict if a given part meets customer requirements and is free from hidden defects, flaws, non-visible geometric fluctuations, and variations in mechanical properties that are critical to the design/analysis process and mission certification. The techniques use Laser Doppler Vibrometry to detect the frequency response spectrum for a given part then process that data with non-p-value statistical techniques (Machine Learning) to develop models that can be “trained” to detect a variety of quality issues. Machine Learning models work best when data from many samples with different unacceptable end-states are available and used to train and develop the models. These end-states could be the result of a variety of unacceptable variations in the MAM process, quality of the precursor powdered metal, quality of the millions of micro-welds that make up the MAM build process, size and number of inclusions and micro flaws in the material as well as residual stresses in the part. In this study, our goals were to (1) use a large enough number of parts to ensure the validity of the machine learning model and (2) focus on geometric defects and the effects of residual stresses. For these initial investigations, we utilized Off-The-Shelf parts to increase statistical reliability, improve our ability to train our Machine Learning Model and refine our experimental protocol while keeping costs within the budget for the research. In the second phase of this research, we will use MAM parts.
In previous papers, we described a diagnostics tool for additive manufacturing products that is based on the concept that the acoustical/vibrational spectrum of an object can be used as a unique signature that characterizes the material and geometry of a product sufficiently to enable its comparison with a perfect reference to identify anomalies. This enables a user to identify rogue parts, such as defective, counterfeit, suspicious or problem parts such as defective or failing to meet specifications. The instrument produces a signature by measuring, with a laser Doppler vibrometer, the vibration of surface points on the part while it is energized by a swept frequency, piezo-electric exciter. Since its first introduction, additional research and development has enhanced, automated, and moved the instrument to a new level in terms of capability and ease of use. This paper describes the latest enhancements, including improved procedures and automation to enable use by an unsophisticated user with minimum training. The latest version provides automatic signal processing and comparison of acoustical signatures of reference and test objects that provide a quantitative grade for the object in terms of material properties, geometrical anomalies, and defects. This is achieved with specially developed algorithms that employ unique types of correlation of vibrational spectra taken from different objects or spectra produced by a simulation of a perfect object. The instrument can quickly produce an optimized correlation coefficient that serves as a numeric grade for a part for identifying suspicious or problem parts such as counterfeits, defective, or failing to meet specifications. The user can set acceptance criteria and initiate a pass or fail signal that can be used for large quantity inspections. Such an instrument is expected to find widespread applications in the AM industry.
The paper discusses the many opportunities for airborne digital holography, shows examples of current applications, describes different recording and data processing techniques, and suggests methods for improving and extending the technology.
We developed a pulsed digital shearography system that utilizes the spatial phase-shifting technique. The system employs a commercial micropolarizer camera and a double pulse laser, which allows for instantaneous phase measurements. The system can measure dynamic deformation of objects as large as 1 m at a 2-m distance during the time between two laser pulses that range from 30 μs to 30 ms. The ability of the system to measure dynamic deformation was demonstrated by obtaining phase wrapped and unwrapped shearograms of a vibrating object.
This paper presents results from simultaneous measurements of fluid density and the resulting wavefront distortions in a
sonic underexpanded jet. The density measurements were carried out using Rayleigh scattering, and the optical
distortions were measured using a wavefront sensor based on phase shifting interferometry. The measurements represent
a preliminary step toward relating wavefront distortions to a specific flow structure. The measured density field is used
to compute the phase distortions using a wave propagation model based on a geometric-optics approximation, and the
computed phase map shows moderate agreement with that obtained using the wavefront sensor.
Measuring and understanding the transient behavior of a surface with high spatial and temporal
resolution are required in many areas of science. This paper describes the development
and application of a high-speed, high-dynamic range, digital holographic interferometer for
high-speed surface contouring with fractional wavelength precision and high-spatial resolution.
The specific application under investigation here is to characterize deformable mirrors
(DM) employed in aero-optics. The developed instrument was shown capable of contouring
a deformable mirror with extremely high-resolution at frequencies exceeding 40 kHz. We
demonstrated two different procedures for characterizing the mechanical response of a surface
to a wide variety of input forces, one that employs a high-speed digital camera and a second
that employs a low-speed, low-cost digital camera. The latter is achieved by cycling the DM
actuators with a step input, producing a transient that typically lasts up to a millisecond before
reaching equilibrium. Recordings are made at increasing times after the DM initiation from
zero to equilibrium to analyze the transient. Because the wave functions are stored and reconstructable,
they can be compared with each other to produce contours including absolute, difference,
and velocity. High-speed digital cameras recorded the wave functions during a single
transient at rates exceeding 40 kHz. We concluded that either method is fully capable of
characterizing a typical DM to the extent required by aero-optical engineers.
The method of buried landmine detection based on using elastic waves in the ground and a laser Doppler vibrometer (LDV) as a vibration sensor has shown excellent performance in field tests. To increase the speed of measurements, a multi-beam laser Doppler vibrometer (MB-LDV) was developed. The system is based on a heterodyne interferometer and is capable of simultaneously measuring the vibration of the ground at 16 points over a span of 1 m with a velocity resolution of less than 1 µm/s. Both digital in-phase and quadrature (I&Q) and analog phase-locked loop (PLL) demodulation have been used for signal processing. The MB-LDV can create a velocity image of the ground surface either in "stop-and-stare" mode or in a continuously scanning mode. The continuously scanning operation results in an increased velocity noise floor due to speckle noise. The speckle noise floor increases with the increase of the speed of the laser beam and can degrade the velocity image of a mine. To overcome the effects of speckle noise, the excitation source must provide a ground vibration velocity higher than the velocity noise floor of the vibrometer. The MB-LDV has been tested at landmine test lanes and shows the ability to detect buried landmine within a one-square-meter area in a time of less than 20 s.
The multi-beam laser Doppler vibrometer (MB-LDV) has been successfully used for acoustic landmine detection in field experiments at an Army test site. Using the MB-LDV in a continuously scanning mode significantly reduces the time of the measurement. However, continuous motion of a laser beam across the ground surface generates noise at the vibrometer output due to dynamic speckles. This speckle noise defines the noise floor and the probability of detection of the system. This paper studies the origins of speckle noise for a continuously scanning LDV. The structure of the speckle field exhibits points of phase singularity that normally coincide with signal dropouts. The signal dropouts and phase singularities can cause spikes in the demodulated velocity signal, which increase the noise in the velocity signal. The response of FM demodulators to input signals causing spikes in the LDV output are investigated in this paper. Methods of spike reduction in the LDV signals have been developed and experimentally investigated.
Several experiments have demonstrated the potential of Laser Doppler Vibrometry, in conjunction with acoustic-toseismic coupling or mechanical shakers, for the detection of buried landmines. For example, experiments conducted by The University Of Mississippi and MetroLaser, Inc. have shown the ability to scan a one square meter area in less than 20 seconds with a 16-beam multi-beam LDV (MB-LDV), and find the landmines under a variety of soil conditions. Some critical requirements for this technology are to reduce the measurement time, increase the spatial resolution, and reduce the size of the systems. In this paper, MetroLaser presents data from three optical systems that help achieve these requirements: 1) A Compact MB-LDV, 2) A two dimensional, or Matrix Laser Doppler Vibrometer (MX-LDV), and 3) A Whole-field Digital Vibrometer (WDV). The compact MB-LDV produces a 1-D array of beams, which may be scanned over the target surface with a scanning mirror. The size of the new, compact MB-LDV system has been reduced to approximately 17" x 11" x 9", thus enhancing its capability for field applications. The MX-LDV, to be developed in 2006, produces a 16x16 array of beams over a one meter area, allowing the ground velocity of the entire area to be measured in a single measurement. The WDV uses a camera-based interferometry system to take a snapshot of the ground vibration over a one meter square area with very high spatial resolution. Field tests for this system are scheduled for mid-2006.
Previous results have shown the potential of acoustic-to-seismic coupling with Laser Doppler Vibrometry for the detection of buried landmines. An important objective of the present technology is to improve the spatial resolution and the speed of the measurement. In this paper, MetroLaser reports on a whole-field digital vibrometer (WDV) that measures an entire one meter area with sub-centimeter spatial resolution in just a few seconds. The WDV is based on a dual-pulsed laser such that each pulse illuminates a one meter area on the ground, and the temporal separation between the two laser pulses can be adjusted to match the ground excitation frequency. By sweeping this excitation frequency, a displacement map of the ground at each frequency can be quickly generated. In addition, an innovative speckle repositioning strategy allows for movement of the measurement platform at reasonable speeds while still obtaining measurements with interferometric precision. This paper describes the WDV instrument and presents preliminary experimental results obtained with this system. This research is being supported by the U.S. Army RDECOM CERDEC NVESD under Contract W909MY04-C-0004.
Acoustic-to-seismic coupling-based technology using a multi-beam laser Doppler vibrometer (LDV) as a vibration sensor has proved itself as a potential confirmatory sensor for buried landmine detection. The multi-beam LDV simultaneously measures the vibration of the ground at 16 points spread over a 1-meter line. The multi-beam LDV was used in two modes of operation: stop-and-stare, and continuously scanning beams. The noise floor of measurements in the continuously scanning mode increased with increasing scanning speed. This increase in the velocity noise floor is caused by dynamic speckles. The influence of amplitude and phase fluctuations of the Doppler signal due to dynamic speckles on the phase locked loop (PLL) demodulated output is discussed in the paper. Either airborne sound or mechanical shakers can be used as a source to excite vibration of the ground. A specially-designed loudspeaker array and mechanical shakers were used in the frequency range from 85-2000 Hz to excite vibrations in the ground and elicit resonances in the mine. The efficiency of these two methods of excitation has been investigated and is discussed in the paper. This research is supported by the U. S. Army Research, Development, and Engineering Command, Night, Vision and Electronic Sensors Directorate under Contract DAAB15-02-C-0024.
Acoustic-to-seismic coupling technology using an LDV as a vibration sensor has proved itself as a potential confirmatory sensor for buried landmine detection. One of the most important objectives of this technology is to increase the speed of measurements over traditional point-by-point scanning LDVs. A moving cart that uses 16 LDVs as well as a continuously-scanning single beam LDV have recently been demonstrated to increase the speed of detection. Recently a multi-beam LDV simultaneously probing 16 positions on the ground has been developed and successfully used for landmine detection. In this work, we report on a continuously-scanning multi-beam LDV as a confirmatory sensor for acoustic landmine detection. The multi-beam LDV simultaneously illuminates the ground in 16 points spread over a 1 meter line. A scanning mirror moves all 16 laser beams across the line. The system enables scanning a 1 meter square area in a much shorter time than previous scanning techniques. This material is based upon work supported by the U. S. Army Communications-Electronics Command Night Vision and Electronic Sensors Directorate under Contract DAAB15-02-C-0024.
This paper discusses the performance and experimental results of a multiple beam laser Doppler vibrometer designed to locate buried landmines with the laser-acoustic technique. The device increases the speed of landmine detection by simultaneously probing 16 positions on the ground over a span of 1 meter, and measuring the ground velocity at each of these positions. Experimental results are presented from controlled laboratory experiments as well as from landmine test lanes at the University of Mississippi. In the mine lanes, the multiple beam system is raised to a height of 2.5 meters with a forklift, with the 16 beams spread over a 1 meter line along the mine lane. A motor system then allows the 16 beams to be translated across the mine lane, enabling the system to scan a 1 x 1 meter area in a much shorter time than with previous scanning techniques. The effects of experimental parameters such as platform motion, angle of incidence, speckle dropout, and system depth-of-field will be presented and discussed.
The use of a laser Doppler vibrometer (LDV) to sense the acoustic-to-seismic coupling ratio for buried landmine detection has previously been demonstrated. During these experiments, the LDV is mounted on a fixed platform and the beam moves continuously across the ground. Experiments show that fixed mounted LDV can achieve scanning speeds up to 3.6 km/h for successful detection of buried landmines in outdoor ground. The problems associated with taking a fixed-mount, scanning LDV and transitioning to a mobile system involve such issues as vehicle vibration, additional Doppler bandwidth due to vehicle speed, speckle noise, and sample time vs. spatial averaging. This paper presents the results of field tests with the moving platform on U.S. Army mine lanes showing that many of these issues can be overcome with an appropriately designed moving platform. The testing involved scanning different types of mines at varying depths and different speeds. Different aspects of the experiment are also discussed.
This paper discusses the development and performance of a multi-beam laser Doppler vibrometer specifically designed to locate buried landmines with a laser-acoustic technique. The device aims at increasing the speed of landmine detection with this technique by at least one order of magnitude. The present system is capable of simultaneously probing sixteen positions on the ground over a span of one meter, and of measuring the ground velocity at each of these positions with a velocity resolution of about 1 micrometers /s. This architecture could also be scaled to a larger number of beams or into two dimensions. The present system uses a low (100 kHz) carrier frequency, which enables digital signal processing in a simple architecture. This paper also discusses a numerical model to simulate and predict the performance of the multi-beam vibrometer. In particular, the model attempts to address issues associated with speckle dropout, signal/noise, and maximum scanning velocity.
We report on the development of a versatile and portable optical profilometer and show its applicability for quick and accurate digitization of 3-D objects. The profilometer is an advanced fringe-projection system that uses a calibrated LCD matrix for fringe-pattern generation, a hierarchical sequence of fringe patterns to demodulate the measured phase, and a photogrammetric calibration technique to obtain accurate 3-D data in the measurement volume. The setup in itself is mechanically stable and allows for a measurement volume of about 1x1x0.5 m3. We discuss the calibration of the sensor and demonstrate the process of recording phase data for several sub-views, generating 3-D point clouds from them, and synthesizing the CAD representation of an entire 3-D object by merging the data sets.
High-temperature water vapor imaging based on Raman scattering for hypersonic exhaust diagnostics has been developed. A temperature-independent UV Raman line imaging instrument that is calibrated with room air and readily scaled to large combustion facilities has been tested in a laboratory H2/air combustor. The H2O concentration measurements exhibit a single-shot standard deviation of approximately 8%. In this paper we investigate practical issues concerning the application of UV Raman line imaging for quantitative water vapor measurements.
High temperature water vapor detection in hypersonic exhaust has been the subject of ongoing research in a collaboration between MetroLaser and Vanderbilt University's Department of Mechanical Engineering. In this paper we examine some of the temperature sensitivity issues surrounding water vapor diagnostics based on two-photon fluorescence measurements. We present work which shows a large temperature sensitivity for the two-photon excited fluorescence features for H2O in a hydrogen and air flat flame burner. The spectra are modeled for various temperatures, results are experimentally verified, and recommendations are made.
The use of pulsed laser holography in analyzing the atomization of impinging jets is evaluated using a holographic camera system capable of recording a 3D image of the atomization process in 3 x 10 exp -8 seconds. The holocamera and the experimental configuration and procedure are described in detail. Two nozzles were fabricated to produce 1-mm diameter liquid water jets that impinged at 60 and 90 deg. Holograms were obtained for each nozzle at liquid velocities of 20 and 40 m/s. Analysis of the holograms revealed the evolution of the jets from the plane of emergence through the region of droplet formation. Features of interest included the growth of disturbances prior to the breakup region and the effect of these disturbances on the formation of ligaments and liquid globules. Preliminary analyses show that waves of atomized liquid formed after impingement are closely correlated to waves measured on the jets, leading to the possibility of controlling the atomization process at the nozzle.
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