The need for reliable and cost-effective testing procedures for Additive Manufacturing (AM) is growing. In this Dissertation, the development of a new computational-experimental method based on the realization of specific testing artifacts to address this need is presented. This research is focused on one of the widely utilized AM technologies, Fused Deposition Modeling (FDM), and can be extended to other AM technologies as well. In this method, testing artifacts are designed with simplified boundary conditions and computational domains that minimize uncertainties in the analyses. Testing artifacts are a combination of thin and thick cantilever structures, which allow measurement of natural frequencies, mode shapes, and dimensions as well as distortions and deformations. We apply Optical Non-Destructive Testing (ONDT) together with computational methods on the testing artifacts to predict their natural frequencies, thermal flow, mechanical properties, and distortions as a function of 3D printing parameters. The complementary application of experiments and simulations on 3D printed testing artifacts allows us to systematically investigate the density, porosity, moduli of elasticity, and Poisson’s ratios for both isotropic and orthotropic material properties to better understand relationships between these characteristics and the selected printing parameters. The method can also be adapted for distortions and residual stresses analyses. We optimally collect data using a design of experiments technique that is based on regression models, which yields statistically significant data with a reduced number of iterations. Analyses of variance of these data highlight the complexity and multifaceted effects of different process parameters and their influences on 3D printed part performance. We learned that the layer thickness is the most significant parameter that drives both density and elastic moduli. We also observed and defined the interactions among density, elastic moduli, and Poisson’s ratios with printing speed, extruder temperature, fan speed, bed temperature, and layer thickness quantitatively. This Dissertation also shows that by effectively combining ONDT and computational methods, it is possible to achieve greater understanding of the multiphysics that governs FDM. Such understanding can be used to estimate the physical and mechanical properties of 3D printed components, deliver part with improved quality, and minimize distortions and/or residual stresses to help realize functional components.

La simulation opérationnelle a déjà été développée pour diverses activités dont l'exercice en conditions réelles peut s'avérer coûteux voire dangereux : le pilotage d'avion, les interventions chirurgicales, etc. L'idée consiste à remplacer la réalité par une simulation suffisamment réaliste pour donner l'impression aux utilisateurs qu'ils réalisent réellement l'activité.Le Contrôle Non-Destructif (CND) regroupe l'ensemble des méthodes mises en œuvre pour tester l'intégrité des pièces mécaniques sans les altérer. Dans ce domaine, la simulation opérationnelle n'a été introduite que très récemment par un brevet déposé par Airbus. Cette approche permet de simuler numériquement la présence de défauts sans avoir à les ajouter réellement dans les pièces. Les pièces aéronautiques étant coûteuses, la simulation opérationnelle permet de réduire les coûts liés à la formation des opérateurs, à l'évaluation des performances des méthodes ou aux tests en conditions réelles de nouvelles procédures.La présente thèse vise à développer les outils scientifiques et technologiques nécessaires à donner vie au concept de simulation opérationnelle en CND. Pour remplacer la réalité par la simulation, les défis à relever sont de trois ordres : le réalisme de la simulation, la rapidité des calculs et l'instrumentation. Nous avons choisi d'illustrer ces trois aspects dans le cadre de l'inspection par ultrasons de pièces en matériaux composites. Les modèles de simulation couramment employés --- basés sur la résolution des équations de la physique --- n'offrent pas des temps de calculs suffisamment courts pour satisfaire les pré-requis de la simulation opérationnelle. Par ailleurs, le réalisme des simulations souffre parfois de la difficulté à paramétrer correctement les modèles. Nous explorons donc une autre approche : les modèles sont construits à partir de données expérimentales. Cette stratégie est exploitée pour traiter différents types de phénomènes tels que l'endommagement par impact, le trou à fond plat ou encore les perturbations de la micro-structure des matériaux. Par ailleurs, une solution matérielle et logicielle sont proposées et un premier prototype de simulateur opérationnel est mis au point. Ce système permet d'exploiter les modèles développés et de montrer que les signaux synthétiques peuvent sembler aussi réalistes que la réalité. Cette thèse court ainsi du concept jusqu'au prototype. / Several fields have already adopted the concept of operational simulation to limit risks and costs. For instance, part of the training phase of airline transport pilots or surgerons can now rely on simulations instead of real-life situations.Non-Destructive Testing (NDT) assesses the integrity of structural and mechanical components without damaging them. Operational simulation has drawn attention of the NDT community only recently through an Airbus patent. In this field, the operational simulation can be used to simulate the presence of a defect in a component without actually inserting the defect. For expensive parts such as aeronautical structures, this approach can reduce the costs of training operators, evaluating NDT method performances or testing new procedures in real-conditions.This thesis work aims to apply the concept of operational simulation to NDT. Three main scientific and technological challenges are to be tackled: the simulation realism, the computation speed and the instrumentation. We chose to focus this study on the ultrasound NDT technique applied to composite materials. Classical simulation approaches based on physical equations are not fast enough for a real-time synthesis of ultrasound signals. Moreover, the realism is often limited by the fidelity of the inspection set-up description. For instance, the material properties are not always well-known and bring to a drop of realism. Thus, we investigate an alternative way: the models are built directly from experimental data. This strategy is applied to model the effect of several phenomena such as impact damages, flat bottom holes or material micro-structure. Hardware and software solutions are also studied to propose a first prototype. We have shown that the replacement of real signals by on-the-fly simulated ones is achievable: the simulation is realistic enough to be considered as reality by operators. thus, this thesis work brings the concept to a first prototype dedicated to ultrasound NDT.

De nombreuses structures utilisées industriellement peuvent être considérées comme des guides d'ondes, comme les plaques, les tuyaux ou encore le rails. La maintenance de ces structures nécessite de pouvoir détecter efficacement des défauts internes par le Contrôle Non Destructif. Nous nous intéressons dans ce manuscrit à l'application d'une méthode d'échantillonnage, la Linear Sampling Method, au CND des guides d'ondes élastiques, qui en particulier impose des sollicitations et des mesures à la surface du guide en régime temporel. La stratégie choisie repose sur une formulation modale et multi-fréquentielle de la LSM, spécifique aux guides d'ondes, qui permet une régularisation efficace et de nature physique du problème inverse, qui est par nature mal posé. Cette stratégie permet par ailleurs une optimisation du nombre et de la position des émetteurs et des récepteurs. Nous nous limitons dans un premier temps au cas scalaire du guide d'ondes acoustiques, pour ensuite s'attaquer au cas vectoriel, et par conséquent plus complexe, du guide d'ondes élastiques.L'efficacité de la méthode inverse est dans un premier temps démontrée sur des données artificielles (obtenues numériquement), puis sur des données réelles obtenues à l'aide d'expériences réalisées sur des plaques métalliques. Ces expériences confirment la faisabilité du CND par méthode d'échantillonnage dans un cadre industriel. Dans le cas où une seule sollicitation est réalisée, l'utilisation de la LSM est exclu. Nous utilisons une approche tout à fait différente et dite "extérieure", couplant une formulation mixte de quasi-réversibilité et une méthode de lignes de niveau, pour reconstruire le défaut. / Widely used structures in an industrial context, such as plates, pipes or rails, can be considered as waveguides. Hence efficient Non Destructive Testing techniques are needed in order to detect defects in these structure during their maintenance. This work is about adapting a sampling method, the Linear Sampling Method, to the context of NDT for elastic waveguides. This context implies that the sollicitations and measurements must be on the surface of the waveguide in a time-dependent regime. A modal and multi-frequency formulation of the LSM, specific to waveguides, has been chosen to solve the problem. This formulation allows an efficient and physical regularization of the inverse problem, which is naturally ill-posed. An optimization of the number of sources and measurements and of their positioning is possible thanks to the methodology used to solve the problem. The scalar case of an acoustic waveguide is considered as a first step, while the vectorial case of an elastic waveguide, more complex by nature, is addressed in a second time.The efficiency of the method is at first tested on artificial data (numerically made), and then on real data obtained from experiments on metallic plates. These experiments show the feasibility of using sampling methods for Non Destructive Testing in an industrial context. In the case when only one sollicitation is available, the LSM can not be applied. A completely different approach is then used, which is called the ``exterior'' approach, coupling a mixed formulation of quasi-reversibility and a level-set method in order to recover the shape of the defect.

The objectives of this research were to investigate the sensitivity of two-prong and fourprong resistivity measurements to certain operator-controlled variables and to conduct a direct comparison of the sensitivity of two-prong and four-prong resistivity measurements to certain concrete material variables. Four full-factorial experiments were designed for this research. In the experimentation on operator-controlled variables with two-prong resistivity testing, main effects that are both statistically significant and practically important include hole depth and surface water. In the experimentation on operator-controlled variables with four-prong resistivity testing, probe position, surface water, and prong spacing are all neither statistically significant nor practically important. This high degree of unexplained variation may be of concern to practitioners. In the experimentation on concrete material variables with two-prong and four-prong resistivity testing, main effects that are both statistically significant and practically important include chloride concentration and temperature, both of which exhibit inverse relationships with resistivity. These research findings support several important recommendations for resistivity testing. Operators of the two-prong resistivity device should use an accurately positioned drill stop to ensure that the prepared holes are consistently the correct depth, and they should expect to obtain different values depending on the presence of surface water on the deck surface. Operators considering use of the four-prong resistivity device should not expect the measurements to be sensitive to probe position with respect to rebar, presence of surface water, or prong spacing for conditions similar to those investigated in this research. Operators interested in monitoring resistivity values over time to ascertain material changes in a bridge deck should develop protocols for measuring concrete temperature in the field and subsequently normalizing resistivity measurements to a standard temperature.

<p>Non-destructive characterization of multi-layered structures that can be accessed from only a single side is important for applications such as well-bore integrity inspection. Collimated beam ultrasound systems are a technology for imaging inside multi-layered structures such as geothermal wells. These systems work by using a collimated narrow-band ultrasound transmitter that can penetrate through multiple layers of heterogeneous material. A series of measurements can then be made at multiple transmit frequencies. However, commonly used reconstruction algorithms such as Synthetic Aperture Focusing Technique (SAFT) tend to produce poor quality reconstructions for these systems both because they do not model collimated beam systems and  they do not jointly reconstruct the multiple frequencies.</p> <p><br></p> <p>In this thesis, we first propose a multi-frequency ultrasound model-based iterative reconstruction (UMBIR) algorithm designed for multi-frequency collimated beam ultrasound systems. The combined system targets reflective imaging of heterogeneous, multi-layered structures. For each transmitted frequency band, we introduce a physics-based forward model to accurately account for the propagation of the collimated narrow-band ultrasonic beam through the multi-layered media. We then show how the joint multi-frequency UMBIR reconstruction can be computed by modeling the direct arrival signals, detector noise, and incorporating a spatially varying image prior.</p> <p><br></p> <p>We also propose a ringing artifact reduction method for ultrasound image reconstruction that uses a multi-agent consensus equilibrium (RARE-MACE) framework. Our approach integrates a physics-based forward model that accounts for the propagation of a collimated ultrasonic beam in multi-layered media, a spatially varying image prior, and a denoiser designed to suppress the ringing artifacts that are characteristic of reconstructions from high-fractional bandwidth ultrasound sensor data.</p> <p><br></p> <p>Results using both simulated and experimental data indicate that multi-frequency UMBIR reconstruction yields much higher reconstruction quality than either single frequency UMBIR or SAFT. In addition, our results demonstrate the capability of our RARE-MACE method to suppress ringing artifacts and substantially improve the image quality over single frequency UMBIR and SAFT.</p>

The goal of the research conducted for this master's thesis is to understand if active thermography is a suitable technique to detect (identify) and measure (approximate depth and or size) defects in additive manufacturing (AM) processes. Although other non-destructive measurement techniques exist, active thermography is an attractive option for AM applications because of the short measurement times that could be implemented between each layer of a print, and because of the relatively inexpensive equipment required. However, pulse thermography is typically applied to detect larger defects (>1 mm) in materials with high thermal conductivity. It was uncertain if active thermography was sensitive enough to detect the small defects (μm) commonly introduced during AM. Defects of this size are common in AM, and their presence significantly impacts the mechanical properties of the final part. For this reason, the detection limits of active thermography in common AM materials were investigated. Numerical models were created to simulate the heat transfer during active thermography in AM structures (polymer and stainless steel) with defects of varying size. The models included non-ideal conditions such as spectral in-depth absorption of the irradiative pulse and free convection from the object's surface. The spectral properties of acrylonitrile butadiene styrene (ABS), polylactic acid (PLA), and polyamide 12 (PA 12) were measured (see chapter 2) and used in the numerical models. The numerical data indicates that active thermography is sensitive enough to detect the existence of defects smaller than 100 μm in AM materials (see chapter 3). Furthermore, it demonstrates that the defect aspect ratio (defect diameter divided by defect depth) for which traditional 1D thermography models may be used to approximate the depth of defects in 3D systems is approximately 6 (see chapter 4). In addition, the depth of defects with lower aspect ratios (~4) may also be approximated with relatively low error (~10% error). Non-ideal systems (those with convection and spectral in-depth absorption) were simulated, and figures are provided which facilitate the approximation of defect depth using simple, ideal thermography models. Active thermography has shown potential as being an efficient technique for detecting and measuring small defects common in AM.

Composite structures can lower the weight of an airliner significantly. The increased production cost, however, requires the application of cost-effective design strategies. Hence, a comparative value is required which is used for the evaluation of a design solution in terms of cost and weight. The direct operating cost (DOC) can be used as this comparative value; it captures all costs that arise when the aircraft is flown. In this work, a cost/weight optimization framework for composite structures is proposed. It takes into account manufacturing cost, non-destructive testing cost and the lifetime fuel consumption based on the weight of the aircraft, thus using a simplified version of the DOC as the objective function. First, the different phases in the design of an aircraft are explained. It is then focused on the advantages and drawbacks of composite structures, the design constraints and allowables, and non-destructive inspection. Further, the topics of multiobjective optimization and the combined optimization of cost and weight are addressed. Manufacturing cost can be estimated by means of different techniques; here, feature-based cost estimations and parametric cost estimations proved to be most suitable for the proposed framework. Finally, a short summary of the appended papers is given. The first paper contains a parametric study in which a skin/stringer panel is optimized for a series of cost/weight ratios (weight penalties) and material configurations. The weight penalty, defined as the specific lifetime fuel burn, is dependent on the fuel consumption of the aircraft, the fuel price and the viewpoint of the optimizer. It is concluded that the ideal choice of the design solution is neither low-cost nor low-weight but rather a combination thereof. The second paper proposes the inclusion of non-destructive testing cost in the design process of the component, and the adjustment of the design strength of each laminate according to the inspection parameters. Hence, the scan pitch of the ultrasonic testing is regarded as a variable, representing an index for the (guaranteed) laminate quality. It is shown that the direct operating cost can be lowered when the quality level of the laminate is assigned and adjusted in an early design stage. / QC 20101112

Drilled shafts are deep foundation elements created by excavating cylindrical shafts into the ground and filling them with concrete. Given the types of structures they support, failure to meet their performance criteria can jeopardize public safety and cause severe financial losses. Consequently, quality control measures are warranted to ensure these foundations meet design specifications, particularly with respect to their structural integrity and geotechnical capacity. Due to their inaccessibility, non-destructive testing (NDT) techniques have received much attention for drilled shaft quality control. However, there are limitations in the NDT tools currently used for structural integrity testing. Moreover, there is no current NDT tool to evaluate conditions underlying drilled shaft excavations and aid in verifying geotechnical capacity. The main objective of this research is to examine the development of new NDT methodologies to address some of the limitations in the inspection of drilled shaft structural integrity and geotechnical conditions underlying their excavations. The use of stress waves in large laboratory models is first examined to evaluate the performance of ray-based techniques for detecting anomalies. The study then continues to investigate the improvements offered by using a full waveform inversion (FWI) approach to analyze the stress wave data. A hybrid, multi-scale FWI workflow is recommended to increase the chance of the convergence of the inversion algorithms. Additionally, the benefits of a multi-parameter FWI are discussed. Since FWI is computationally expensive, a sequential optimal experimental design (SOED) analysis is proposed to determine the optimal hardware configurations for each application. The resulting benefit-cost curves from this analysis allow for designing an NDT survey that matches the available resources for the project. / Civil Engineering

A change in a part's response to vibrations can be measured and utilized as a non-destructive testing method to detect deviations in the part's materials or geometry through processes such as laser acoustic resonance spectroscopy. This work focuses on leveraging vibration resonance to detect flaws in prints produced through additive friction stir deposition that arise through environmental contamination. More specifically, the use case considered is the printing of AA7075 in an iron oxide rich environment, where iron oxide dust or powder could accidentally be stirred into the printed material creating a print flaw. The modeling of printed parts contaminated with iron oxide to predict their natural frequencies is examined. Two different finite element models are discussed, which were created to represent contamination flaws with and without voids. The first model considers the case where a part is void-free. In this case, the model assumes a solid, homogeneous material condition in the stir region. The second model considers the case where voids are present in the part. This model leverages x-ray computed tomography data to build a representative mesh. These models show that with a well-understood part and corresponding flaw, it is possible to predict the natural frequencies of a flawed part. By leveraging the part vibration measurements and model predictions of known defects, it may be possible to gain insights into and characterize unknown print flaws. / Master of Science / An important aspect of product or part creation is checking consistency between parts. Methods that can verify a part is good without damaging the part are valuable, especially when only a few parts are being made, or there is a high chance of something going wrong. One way of checking a part is to shake it and watch how it reacts and bends. If there is a difference in how a part reacts to the shaking from a known good part, then there is a problem. This work examines creating computer simulations to predict how a part should react to shaking when it is good and how it should react when it has flaws. This work considers flaws caused by debris from the environment during part creation. This work also considers whether such debris causes holes or voids to form in the parts and conducts predictions with the holes included.

The focus in this work is on the use of ultrasonic testing as a method for inspecting components manufactured through additive manufacturing (AM) processes. The research is rooted in the need for effective non-destructive testingtechniques that can adapt to the unique challenges posed by AM-produced materials, including complex defect geometries and surface conditions. Ultrasonic testing is a versatile form of non-destructive testing, offering theability to detect internal flaws, such as voids, cracks, and inclusions, with highprecision and in real-time. Unlike many competing methods, ultrasonic testing works on most types of materials. Ultrasonic testing has been applied forinspection purposes for a long time. Now with emerging manufacturing methods, there is a need for evaluation techniques to keep up with this development.New data processing algorithms open up possibilities of extracting more information from the acquired signal. The thesis provides a review of UT’s capabilities in detecting and classifyingdefects within AM components, with a particular emphasis on the subtletiesintroduced by the layer-by-layer construction method inherent to AM technologies. The work advances development and validation of simulation modelsaimed at predicting the ultrasonic response from manufactured defects. Thesemodels are crucial for understanding the interaction between ultrasound wavesand material anomalies, offering insights into the potential for enhanced defectdetection strategies. The research also explores the practical case of integrating UT into the quality assurance processes by relying on mathematical simulation rather than experimental data. The findings suggest avenues for the refinement of creation of inspection procedure, including the the use of meta-models to cheaply acquire worst-case scenario defects, to better accommodate the specificities of AM materials. / Den här avhandlingen handlar om ultraljudsprovning av additivt tillverkade metalkomponenter. Ultraljud är en av flera metoder som används för att detektera defekter i komponenter utan att förstöra komponenten i processen. Samlingsnamnet för dessa metoder är oförstörande provning. Oförstörande provning är en viktig pusselbit i samhällets säkerhet då det möjliggör identifiering och utvärdering av potentiella defekter i material, vilket förebygger olyckor och strukturella fel. Vidare är det en viktig del inom hållbar utveckling genom att maximera nyttjandet av komponenter då dessa inte behöver ersättas med ett överdrivet försiktigt underhållsintervall. Ultraljudsprovning fungerar genomatt ultraljud introduceras in i en komponent, varefter en givare registrerar ekon som uppstår när ljudvågorna interagerar med eventuella defekter. Detta möjliggör både lokalisering och storleksbedömning av defekter, t.ex. sprickor, bindfel eller porer. Resultaten av den här avhandlingen syftar till att ge förutsättningar för att förbättra tolkningen av dessa signaler, dels genom att experimentellt validera simuleringsmodeller, samt tillämpning av dessa modeller för att utveckla en metamodell för att prediktera amplitudsvaret från en mängd defekter inom en viss parameterrymd. Med verktyg som detta kan billigare inspektionsprocedurer möjliggöras genom att man till större del kan förlita sig på simulering av signaler snarare än att skaffa stort underlag med experimentell data. / <p>Paper A, B and C are not included in the eletronic version. Paper C is under submission.</p>