Enhanced generation of quasi-static components of ultrasonic wave and its applications for stress assessment of additive manufacturing components

Abstract The residual stress in components fabricated by additive manufacturing (AM) is notably affected by printing parameters and AM machine configurations. Developing a valid and accurate stress evaluation technique for AM components is imperative for ensuring their quality and service safety. Quasi-static component (QSC) generation, a typical acoustic nonlinear response of ultrasonic waves, offers a highly sensitive approach for nondestructively evaluating material properties. However, the inherently low signal-to-noise ratio (SNR) typical of nonlinear acoustic response has constrained its practical implementation. To address this limitation, ultrasonic resonance is employed to enhance the generation of QSC, and the proposed method is applied to assess the stress state in AM components. Both numerical and experimental results demonstrate that ultrasonic wave resonance can effectively enhance the QSC generation. The phase reversal technique is introduced to improve the reliability and sensitivity of the proposed method. Additionally, this study investigates the influence of stress states on QSC generation. Findings reveal that the nonlinear parameter derived from QSC exhibits significant variations under increasing external tensile stress loads, with enhanced sensitivity and accuracy. Nevertheless, the observed alterations in the measured linear acoustic parameters are negligible. This method integrates the unique feature of ultrasonic wave resonance with the advantages of the QSC, offering a reliable and sensitive means for stress assessment of AM components.