Other Funded Projects

Core temperature and residual stress measurement using laser ultrasound for sustainable additive manufacturing

Metal additive manufacturing (AM) has become increasingly popular across various industries worldwide, particularly in the UK. Sectors such as industrial machinery, aerospace, and automotive are leveraging the unique advantages of metal AM, including significant reductions in raw material waste and the ability to produce highly complex parts. Additionally, compared to traditional methods like casting, metal AM offers shorter production cycles, which helps accelerate technological innovation. 

To ensure consistent quality and performance across applications, it is essential to monitor multiple part properties and process parameters during manufacturing. Two critical parameters are in-process temperature and residual stress. The temperature of the substrate or previously deposited layer directly affects the part’s structural integrity and dimensional accuracy. Meanwhile, unmanaged residual stresses can result in part distortion or failure. 

This project aims to develop a novel, non-invasive, and non-destructive method for measuring internal temperature and residual stress in AM parts using laser ultrasound. Currently, no such method exists for this specific application. By employing ultrasonic thermometry, internal temperatures can be measured more accurately than with existing surface-based systems. This advancement will enable better control of AM process parameters, in turn reducing material waste and minimizing rework. 

This project is made possible by the EPSRC funded “Innovation Launchpad Network’s Researcher in Residence” Programme and is being conducted at the Manufacturing Technology Centre (MTC) in collaboration with the National Centre for Additive Manufacturing. 

Learn more about the Innovation Launchpad Network.