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 effect of ultrasonic waves, offers a highly sensitive approach for nondestructively evaluating material properties. However, the inherently low signal-to-noise ratio typical of nonlinear acoustic effects has constrained its practical implementation. Currently, methodologies capable of directly enhancing the generation of nonlinear effects remain relatively scarce. In fact, enhancing the generation of nonlinear responses is of decisive significance for achieving efficient acquisition and precise analysis of nonlinear ultrasonic waves. To address this limitation, this study innovatively integrates ultrasonic resonance with nonlinear ultrasonic technology, leveraging the amplification effect of ultrasonic resonance on wave energy to achieve enhanced generation of nonlinear responses. 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 further applies this enhancement effect to stress assessment, significantly improving the sensitivity of QSC to stress variations. 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 novel approach for effective measurement of nonlinear ultrasonic waves.