A Comparative Study on Ultrasonic Propagation Characteristics and Defect Detection of Metal Material Additive Manufacturing Using Deep Learning Algorithm

  • Conference paper
  • First Online:
Advances in Engineering Design (FLAME 2022)

Abstract

The method of measuring the thickness of the specimen using bulk waves is an effective technique for measuring the thickness of the structure in the ultrasonic non-destructive technique. The principle of measuring the bulk wave thickness can be used to determine the thickness of the structure using the correlation between the reciprocating time when the ultrasonic waves pass through the internal material of the specimen and return from the bottom. As interest in 3D printers has increased recently, this paper studied how to process ultrasound A-scan signals reflected from the bottom when measuring the thickness of a structure using the above method. For the experiment, the step wedge manufactured in units of 5 mm from 5 to 25 mm with a 1018 steel material was repeatedly tested using volumetric waves, a result value was derived, and data was generated by imaging it, and then the neural network was trained using MATLAB’s Pre-trained Deep Neural Networks. Afterward, the A-scan image of step wedge produced by 3D printer was added to the learned network and used as test data, indicating that the classification according to thickness was very good. Finally, the results were confirmed by training to classify the image results of the defective step wedge produced by the 3D printer. This study is believed to be effective as a basic study in comparing specimens produced with 3D printers through Deep Learning and observing defects.

This is a preview of subscription content, log in via an institution to check access.

Access this chapter

Springer+ Basic
EUR 32.99 /Month
  • Get 10 units per month
  • Download Article/Chapter or Ebook
  • 1 Unit = 1 Article or 1 Chapter
  • Cancel anytime
Subscribe now
Chapter
EUR 29.95
Price includes VAT (Germany)
  • Available as PDF
  • Read on any device
  • Instant download
  • Own it forever
eBook
EUR 128.39
Price includes VAT (Germany)
  • Available as EPUB and PDF
  • Read on any device
  • Instant download
  • Own it forever
Softcover Book
EUR 171.19
Price includes VAT (Germany)
  • Compact, lightweight edition
  • Dispatched in 3 to 5 business days
  • Free ship** worldwide - see info

Tax calculation will be finalised at checkout

Purchases are for personal use only

Institutional subscriptions

Similar content being viewed by others

References

  1. Seo J-S, Lee B-C, Kim Y-Y (2020) Uniformity and accuracy of mortar layer thickness for the quality evaluation of 3D printer output. J Korea Concr Inst 32:371–377. https://doi.org/10.4334/JKCI.2020.32.4.371

    Article  Google Scholar 

  2. Elsaadouny M, Barowski J, Rolfes I (2019) A convolutional neural network for the non-destructive testing of 3D-printed samples. In: 2019 44th International conference on infrared, millimeter, and terahertz waves (IRMMW-THz). IEEE, pp 1–2. https://doi.org/10.1109/IRMMW-THz.2019.8874445

  3. Elsaadouny M, Barowski J, Rolfes I (2019) Non-destructive testing of 3D-printed samples based on machine learning. In: 2019 IEEE MTT-S Int Microw Work Ser Adv Mater Process RF THz Applications, pp 22–24

    Google Scholar 

  4. Sharma SK, Lee J, Jang H-L (2022) Mathematical modeling and simulation of suspended equipment impact on car body modes. Machines 10:192. https://doi.org/10.3390/machines10030192

    Article  Google Scholar 

  5. Sharma SK, Sharma RC, Lee J (2022) In situ and experimental analysis of longitudinal load on car body fatigue life using nonlinear damage accumulation. Int J Damage Mech 31:605–622. https://doi.org/10.1177/10567895211046043

    Article  Google Scholar 

  6. Sharma SK, Sharma RC, Lee J (2021) Effect of rail vehicle-track coupled dynamics on fatigue failure of coil spring in a suspension system. Appl Sci 11:2650. https://doi.org/10.3390/app11062650

    Article  Google Scholar 

  7. Bhardawaj S, Sharma RC, Sharma SK, Sharma N (2021) On the planning and construction of railway curved track. Int J Veh Struct Syst 13:151–159. https://doi.org/10.4273/ijvss.13.2.04

    Article  Google Scholar 

  8. Mohapatra S, Mohanty D, Mohapatra S, Sharma S, Dikshit S, Kohli I, Samantaray DP, Kumar R, Kathpalia M (2021) Biomedical application of polymeric biomaterial: polyhydroxybutyrate. In: Bioresource utilization and management: applications in therapeutics, biofuels, agriculture, and environmental science. CRC Press, pp 1–14

    Google Scholar 

  9. Sharma RC, Sharma S, Sharma N, Sharma SK (2021) Linear and nonlinear analysis of ride and stability of a three-wheeled vehicle subjected to random and bump inputs using bond graph and Simulink methodology. SAE Int J Commer Veh 14. https://doi.org/10.4271/02-15-01-0001

  10. Wu Q, Cole C, Spiryagin M, Chang C, Wei W, Ursulyak L, Shvets A, Murtaza MA, Mirza IM, Zhelieznov К, Mohammadi S, Serajian H, Schick B, Berg M, Sharma RC, Aboubakr A, Sharma SK, Melzi S, Di Gialleonardo E, Bosso N, Zampieri N, Magelli M, Ion CC, Routcliffe I, Pudovikov O, Menaker G, Mo J, Luo S, Ghafourian A, Serajian R, Santos AA, Teodoro ÍP, Eckert JJ, Pugi L, Shabana A, Cantone L (2021) Freight train air brake models. Int J Rail Transp:1–49. https://doi.org/10.1080/23248378.2021.2006808

  11. Sharma RC, Sharma S, Sharma SK, Sharma N, Singh G (2021) Analysis of bio-dynamic model of seated human subject and optimization of the passenger ride comfort for three-wheel vehicle using random search technique. Proc Inst Mech Eng Part KJ Multi-body Dyn 235:106–121. https://doi.org/10.1177/1464419320983711

  12. Lee J, Han J, Sharma SK (2021) Structural analysis on the separated and integrated differential gear case for the weight reduction. In: Joshi P, Gupta SS, Shukla AK, Gautam SS (eds) Advances in engineering design. Lecture notes in mechanical engineering, pp 175–181. https://doi.org/10.1007/978-981-33-4684-0_18

  13. Sharma SK, Lee J (2020) Finite element analysis of a fishplate rail joint in extreme environment condition. Int J Veh Struct Syst 12:503–506. https://doi.org/10.4273/ijvss.12.5.03

    Article  Google Scholar 

  14. Sharma RC, Sharma SK, Sharma N, Sharma S (2020) Analysis of ride and stability of an ICF railway coach. Int J Veh Noise Vib 16:127. https://doi.org/10.1504/IJVNV.2020.117820

    Article  Google Scholar 

  15. Mohapatra S, Pattnaik S, Maity S, Mohapatra S, Sharma S, Akhtar J, Pati S, Samantaray DP, Varma A (2020) Comparative analysis of PHAs production by Bacillus megaterium OUAT 016 under submerged and solid-state fermentation. Saudi J Biol Sci 27:1242–1250. https://doi.org/10.1016/j.sjbs.2020.02.001

    Article  Google Scholar 

  16. Sharma SK, Mohapatra S, Sharma RC, Alturjman S, Altrjman C, Mostarda L, Stephan T (2022) Retrofitting existing buildings to improve energy performance. Sustainability 14:666. https://doi.org/10.3390/su14020666

    Article  Google Scholar 

  17. Bhardawaj S, Sharma RC, Sharma SK (2020) Development of multibody dynamical using MR damper based semi-active bio-inspired chaotic fruit fly and fuzzy logic hybrid suspension control for rail vehicle system. Proc Inst Mech Eng Part K J Multi-body Dyn 234:723–744. https://doi.org/10.1177/1464419320953685

  18. Sharma SK, Phan H, Lee J (2020) An application study on road surface monitoring using DTW based image processing and ultrasonic sensors. Appl Sci 10:4490. https://doi.org/10.3390/app10134490

    Article  Google Scholar 

  19. Sharma SK, Sharma RC, Sharma N (2020) Combined multi-body-system and finite element analysis of a rail locomotive crashworthiness. Int J Veh Struct Syst 12:428–435. https://doi.org/10.4273/ijvss.12.4.15

    Article  Google Scholar 

  20. Sharma SK, Lee J (2020) Design and development of smart semi active suspension for nonlinear rail vehicle vibration reduction. Int J Struct Stab Dyn 20:2050120. https://doi.org/10.1142/S0219455420501205

    Article  MathSciNet  Google Scholar 

  21. Bhardawaj S, Sharma RC, Sharma SK (2020) Development in the modeling of rail vehicle system for the analysis of lateral stability. Mater Today Proc 25:610–619. https://doi.org/10.1016/j.matpr.2019.07.376

    Article  Google Scholar 

  22. Bhardawaj S, Sharma R, Sharma S (2020) Ride analysis of track-vehicle-human body interaction subjected to random excitation. J Chinese Soc Mech Eng 41:237–236. https://doi.org/10.29979/JCSME

  23. Palli S, Sharma RC, Sharma SK, Chintada VB (2020) On methods used for setting the curve for railway tracks. J Crit Rev 7:241–246

    Google Scholar 

  24. Sharma RC, Sharma SK, Palli S (2020) Linear and non-linear stability analysis of a constrained railway wheelaxle. Int J Veh Struct Syst 12:128–133. https://doi.org/10.4273/ijvss.12.2.04

    Article  Google Scholar 

  25. Acharya A, Gahlaut U, Sharma K, Sharma SK, Vishwakarma PN, Phanden RK (2020) Crashworthiness analysis of a thin-walled structure in the frontal part of automotive chassis. Int J Veh Struct Syst 12:517–520. https://doi.org/10.4273/ijvss.12.5.06

    Article  Google Scholar 

  26. Sharma S, Sharma RC, Sharma SK, Sharma N, Palli S, Bhardawaj S (2020) Vibration isolation of the quarter car model of road vehicle system using dynamic vibration absorber. Int J Veh Struct Syst 12:513–516. https://doi.org/10.4273/ijvss.12.5.05

    Article  Google Scholar 

  27. Vishwakarma PN, Mishra P, Sharma SK (2022) Characterization of a magnetorheological fluid damper a review. Mater Today Proc 56:2988–2994. https://doi.org/10.1016/j.matpr.2021.11.143

    Article  Google Scholar 

  28. Bhardawaj S, Sharma RC, Sharma SK (2020) Analysis of frontal car crash characteristics using ANSYS. Mater Today Proc 25:898–902. https://doi.org/10.1016/j.matpr.2019.12.358

    Article  Google Scholar 

  29. Sharma RC, Sharma S, Sharma SK, Sharma N (2020) Analysis of generalized force and its influence on ride and stability of railway vehicle. Noise Vib Worldw 51:95–109. https://doi.org/10.1177/0957456520923125

    Article  MATH  Google Scholar 

  30. Lee J, Sharma SK (2020) Numerical investigation of critical speed analysis of high-speed rail vehicle. 한국정밀공학회 학술발표대회 논문집Korean Soc Precis Eng 696

    Google Scholar 

  31. Sharma SK, Saini U, Kumar A (2019) Semi-active control to reduce lateral vibration of passenger rail vehicle using disturbance rejection and continuous state damper controllers. J Vib Eng Technol 7:117–129. https://doi.org/10.1007/s42417-019-00088-2

    Article  Google Scholar 

  32. Sinha AK, Sengupta A, Gandhi H, Bansal P, Agarwal KM, Sharma SK, Sharma RC, Sharma SK (2019) Performance enhancement of an all-terrain vehicle by optimizing steering, powertrain and brakes. In: Advances in engineering design, pp 207–215. https://doi.org/10.1007/978-981-13-6469-3_19

  33. Choppara RK, Sharma RC, Sharma SK, Gupta T (2019) Aero dynamic cross wind analysis of locomotive. IOP Conf Ser: Mater Sci Eng:12035

    Google Scholar 

  34. Goswami B, Rathi A, Sayeed S, Das P, Sharma RC, Sharma SK (2019) Optimization design for aerodynamic elements of Indian locomotive of passenger train. In: Advances in engineering design. Lecture notes in mechanical engineering. Springer, Singapore, pp 663–673. https://doi.org/10.1007/978-981-13-6469-3_61

  35. Sharma SK, Sharma RC (2019) Pothole detection and warning system for Indian roads. In: Advances in interdisciplinary engineering, pp 511–519. https://doi.org/10.1007/978-981-13-6577-5_48

  36. Goyal S, Anand CS, Sharma SK, Sharma RC (2019) Crashworthiness analysis of foam filled star shape polygon of thin-walled structure. Thin-Walled Struct. 144:106312. https://doi.org/10.1016/j.tws.2019.106312

    Article  Google Scholar 

  37. Bhardawaj S, Chandmal Sharma R, Kumar Sharma S (2019) Development and advancement in the wheel-rail rolling contact mechanics. IOP Conf Ser Mater Sci Eng 691:012034. https://doi.org/10.1088/1757-899X/691/1/012034

    Article  Google Scholar 

  38. Sharma RC, Sharma SK (2022) Ride analysis of road surface-three-wheeled vehicle-human subject interactions subjected to random excitation. SAE Int J Commer Veh 15. https://doi.org/10.4271/02-15-03-0017

  39. Sharma SK (2019) Multibody analysis of longitudinal train dynamics on the passenger ride performance due to brake application. Proc Inst Mech Eng Part K J Multi-body Dyn 233:266–279. https://doi.org/10.1177/1464419318788775.

  40. Bhardawaj S, Chandmal Sharma R, Kumar Sharma S (2019) A survey of railway track modelling. Int J Veh Struct Syst 11:508–518. https://doi.org/10.4273/ijvss.11.5.08

    Article  Google Scholar 

  41. Sharma SK, Sharma RC, Lee J, Jang H-L (2022) Numerical and experimental analysis of DVA on the flexible-rigid rail vehicle car body resonant vibration. Sensors 22:1922. https://doi.org/10.3390/s22051922

    Article  Google Scholar 

  42. Choi S, Lee J, Sharma SK (2021) A study on the performance evaluation of hydraulic tank injectors. In: Advances in engineering design: select proceedings of FLAME 2020. Springer Singapore, pp 183–190. https://doi.org/10.1007/978-981-33-4684-0_19

  43. Sharma SK, Sharma RC (2021) Multi-objective design optimization of locomotive nose. In: SAE technical paper, pp 1–10. https://doi.org/10.4271/2021-01-5053

  44. Sharma SK, Lee J (2021) Crashworthiness analysis for structural stability and dynamics. Int J Struct Stab Dyn 21:2150039. https://doi.org/10.1142/S0219455421500395

    Article  Google Scholar 

  45. Sharma RC, Palli S, Sharma N, Sharma SK (2021) Ride behaviour of a four-wheel vehicle using h infinity semi-active suspension control under deterministic and random inputs. Int J Veh Struct Syst 13:234–237. https://doi.org/10.4273/ijvss.13.2.18

    Article  Google Scholar 

  46. Sharma RC, Palli S, Sharma SK, Roy M (2018) Modernization of railway track with composite sleepers. Int J Veh Struct Syst 9:321–329

    Google Scholar 

  47. Sharma SK, Kumar A (2018) Disturbance rejection and force-tracking controller of nonlinear lateral vibrations in passenger rail vehicle using magnetorheological fluid damper. J Intell Mater Syst Struct 29:279–297. https://doi.org/10.1177/1045389X17721051

    Article  Google Scholar 

  48. Sharma SK, Kumar A (2017) Ride performance of a high speed rail vehicle using controlled semi active suspension system. Smart Mater Struct 26:055026. https://doi.org/10.1088/1361-665X/aa68f7

    Article  Google Scholar 

  49. Sharma SK, Kumar A (2016) The impact of a rigid-flexible system on the ride quality of passenger bogies using a flexible car body. In: Pombo J (ed) Proceedings of the third international conference on railway technology: research, development and maintenance, Stirlingshire, UK. Civil-Comp Press, 2016, Stirlingshire, UK, p 87. https://doi.org/10.4203/ccp.110.87

  50. Sharma SK, Chaturvedi S (2016) Jerk analysis in rail vehicle dynamics. Perspect Sci 8:648–650. https://doi.org/10.1016/j.pisc.2016.06.047

    Article  Google Scholar 

  51. Kulkarni D, Sharma SK, Kumar A (2016) Finite element analysis of a fishplate rail joint due to wheel impact. In: International conference on advances in dynamics, vibration and control (ICADVC-2016) NIT Durgapur, India February 25–27, 2016. National Institute of Technology Durgapur, Durgapur, India

    Google Scholar 

  52. Sharma SK, Kumar A (2016) Dynamics analysis of wheel rail contact using FEA. Procedia Eng. 144:1119–1128. https://doi.org/10.1016/j.proeng.2016.05.076

    Article  Google Scholar 

  53. Sharma SK, Sharma RC, Kumar A, Palli S (2015) Challenges in rail vehicle-track modeling and simulation. Int J Veh Struct Syst 7:1–9. https://doi.org/10.4273/ijvss.7.1.01

    Article  Google Scholar 

  54. Sharma SK, Kumar A, Sharma RC (2014) Challenges in railway vehicle modeling and simulations. In: International conference on newest drift in mechanical engineering (ICNDME-14) , December 20–21, M. M. University, Mullana, India. Maharishi Markandeshwar University, Mullana—Ambala, pp 453–459

    Google Scholar 

  55. Sharma SK, Kumar A (2014) A comparative study of Indian and worldwide railways. Int J Mech Eng Robot Res 1:114–120

    Google Scholar 

  56. Sharma SK, Lavania S (2013) Green manufacturing and green supply chain management in India: a review. In: Futuristic trends in mechanical and industrial engineering. JECRC UDML College of Engineering, pp 1–8

    Google Scholar 

  57. Sharma SK (2013) Zero energy building envelope components: a review. Int J Eng Res Appl 3:662–675

    Google Scholar 

  58. Sharma SK, Kumar A (2018) Impact of longitudinal train dynamics on train operations: a simulation-based study. J Vib Eng Technol 6:197–203. https://doi.org/10.1007/s42417-018-0033-4

    Article  Google Scholar 

  59. Sharma SK, Lavania S (2013) An autonomous metro: design and execution. In: Futuristic trends in mechanical and industrial engineering. JECRC UDML College of Engineering, Jaipur, pp 1–8

    Google Scholar 

  60. Sharma SK, Sharma RC (2018) An investigation of a locomotive structural crashworthiness using finite element simulation. SAE Int J Commer Veh 11:235–244. https://doi.org/10.4271/02-11-04-0019

    Article  Google Scholar 

  61. Sharma RC, Sharma SK (2018) Sensitivity analysis of three-wheel vehicle’s suspension parameters influencing ride behavior. Noise Vib Worldw 49:272–280. https://doi.org/10.1177/0957456518796846

    Article  Google Scholar 

  62. Sharma RC, Sharma SK, Palli S (2018) Rail vehicle modelling and simulation using Lagrangian method. Int J Veh Struct Syst 10:188–194. https://doi.org/10.4273/ijvss.10.3.07

    Article  Google Scholar 

  63. Sharma SK, Kumar A (2018) Ride comfort of a higher speed rail vehicle using a magnetorheological suspension system. Proc Inst Mech Eng Part K J Multi-body Dyn 232:32–48. https://doi.org/10.1177/1464419317706873

  64. Sharma SK, Sharma RC (2018) Simulation of quarter-car model with magnetorheological dampers for ride quality improvement. Int J Veh Struct Syst 10:169–173. https://doi.org/10.4273/ijvss.10.3.03

    Article  Google Scholar 

  65. Palli S, Koona R, Sharma SK, Sharma RC (2018) A review on dynamic analysis of rail vehicle coach. Int J Veh Struct Syst 10:204–211. https://doi.org/10.4273/ijvss.10.3.10

    Article  Google Scholar 

  66. Sharma SK, Kumar A (2017) Impact of electric locomotive traction of the passenger vehicle ride quality in longitudinal train dynamics in the context of Indian railways. Mech Ind 18:222. https://doi.org/10.1051/meca/2016047

    Article  Google Scholar 

  67. Sharma SK, Lavania S (2011) Skin effect in high speed VLSI on-chip interconnects. In: International conference on VLSI, communication and networks, V-CAN. Institute of Engineering & Technology, Alwar, pp 1–8

    Google Scholar 

  68. Lavania S, Sharma SK (2011) An explicit approach to compare crosstalk noise and delay in VLSI RLC interconnect modeled with skin effect with step and ramp input. J VLSI Des. Tools Technol 1:1–8

    Google Scholar 

  69. Dao DK, Ngo V, Phan H, Pham CV, Lee J, Bui TQ (2020) Rayleigh wave motions in an orthotropic half-space under time-harmonic loadings: a theoretical study. Appl Math Model 87:171–179. https://doi.org/10.1016/j.apm.2020.06.006

    Article  MathSciNet  MATH  Google Scholar 

  70. Park J, Lee J, Le Z, Cho Y (2020) High-precision noncontact guided wave tomographic imaging of plate structures using a DHB algorithm. Appl Sci 10:4360. https://doi.org/10.3390/app10124360

    Article  Google Scholar 

  71. Lee J, Ngo V, Phan H, Nguyen T, Dao DK, Cho Y (2019) Scattering of surface waves by a three-dimensional cavity of arbitrary shape: analytical and experimental studies. Appl Sci 9:5459. https://doi.org/10.3390/app9245459

    Article  Google Scholar 

  72. Park J, Lee J, Jeong S-G, Cho Y (2019) A study on guided wave propagation in a long distance curved pipe. J Mech Sci Technol 33:4111–4117. https://doi.org/10.1007/s12206-019-0806-z

    Article  Google Scholar 

  73. Zhu B, Lee J (2019) A study on fatigue state evaluation of rail by the use of ultrasonic nonlinearity. Materials (Basel) 12:2698. https://doi.org/10.3390/ma12172698

  74. Park B, Kim J, Lee J, Kang M-S, An Y-K (2018) Underground object classification for urban roads using instantaneous phase analysis of ground-penetrating radar (GPR) data. Remote Sens 10:1417. https://doi.org/10.3390/rs10091417

    Article  Google Scholar 

Download references

Acknowledgements

This work was supported by Korea Institute of Energy Technology Evaluation and Planning (KETEP) grant funded by the Korea government (MOTIE) (20214000000480, Development of R&D engineers for combined cycle power plant technologies).

Author information

Authors and Affiliations

Authors

Corresponding author

Correspondence to Jaesun Lee .

Editor information

Editors and Affiliations

Rights and permissions

Reprints and permissions

Copyright information

© 2023 The Author(s), under exclusive license to Springer Nature Singapore Pte Ltd.

About this paper

Check for updates. Verify currency and authenticity via CrossMark

Cite this paper

Song, H., Park, J., Sharma, S.K., Lee, J. (2023). A Comparative Study on Ultrasonic Propagation Characteristics and Defect Detection of Metal Material Additive Manufacturing Using Deep Learning Algorithm. In: Sharma, R., Kannojiya, R., Garg, N., Gautam, S.S. (eds) Advances in Engineering Design. FLAME 2022. Lecture Notes in Mechanical Engineering. Springer, Singapore. https://doi.org/10.1007/978-981-99-3033-3_15

Download citation

  • DOI: https://doi.org/10.1007/978-981-99-3033-3_15

  • Published:

  • Publisher Name: Springer, Singapore

  • Print ISBN: 978-981-99-3032-6

  • Online ISBN: 978-981-99-3033-3

  • eBook Packages: EngineeringEngineering (R0)

Publish with us

Policies and ethics

Navigation