Abstract: A system for in-situ monitoring an additive manufacturing build includes a recoater and an eddy current array probe (ECAP) coupled to the recoater. The ECAP includes three rows of sensor elements, and a drive line arranged in a semi-circular wave pattern extending through each of the three rows of sensor elements. The semi-circular wave pattern is defined by a wavelength, and the semi-circular wave pattern of the drive line extending through a particular row of sensor elements is offset by a fraction of the wavelength relative to the semi-circular wave pattern of the drive line extending through an adjacent row of sensor elements.

Abstract: The method includes positioning a probe of the phased array ultrasound system on the mounting portion of the anisotropic rotor blade at the axial centerline. The method further includes scanning a sector of the anisotropic rotor blade along the axial centerline with the probe of the phased array ultrasound system. The method further includes determining a magnitude and a time delay of an echo signal corresponding with a geometric fiducial marker. The method further includes adjusting a position of one of the anisotropic rotor blade or the probe based on the magnitude and/or the time delay of the echo signal corresponding with the geometric fiducial marker. The method further includes repeating the scanning, determining, and adjusting steps until the magnitude and the time delay of the echo signal corresponding with the geometric fiducial marker is within a predetermined maximum echo range. The method further includes scanning the anisotropic rotor blade for defects.

Abstract: Ultrasound inspection methods for noisy materials and related probes are disclosed to inspect a defect in a cast material that use polycarbonate delay layers having a first surface configured to be disposed on a surface of the cast material; and an acoustic crystal element disposed on a second surface of the polycarbonate delay layer.