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<p>Reference reflectors are essential in ultrasonic testing (UT) for setting sensitivity and sizing flaws. Traditionally manufactured flat-bottom holes (FBHs) are well-established disc-shaped reflectors (DSRs) used for sensitivity setting of the UT system and sizing of detected flaws, but they are open to the surface. With the advent of additive manufacturing (AM), there is now a capability to fabricate alternative DSRs that can be embedded within components of finite thickness. This approach allows a closer resemblance to volumetric flaws. In this study, AM-produced DSRs are explored for UT sensitivity setting and flaw sizing, demonstrating their potential to overcome the limitations of traditional manufacturing methods that rely on drilling with flat-bottom drills. The DSRs in the AM blocks were designed in the CAD model and produced as fully integrated features during the direct metal laser sintering (DMLS) process. Two DMLS blocks were fabricated with varying layer thicknesses and reflector orientations, incorporating both embedded and surface-open reflectors. Their ultrasonic responses were compared to those from traditionally manufactured FBHs using the Distance-Gain-Size (DGS) technique. The study analysed A-scan echo patterns and equivalent reflector sizes (ERSs). Results show that AM-produced DSRs can provide ultrasonic responses similar to traditional FBHs with embedded reflectors, especially when aligned with the layer direction. These findings demonstrate the feasibility of using embedded AM-produced DSRs for UT sensitivity setting and flaw sizing in AM parts, thereby enabling tailored reference block design for non-destructive evaluation of both AM and traditionally manufactured parts.</p>

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Comparative evaluation of traditional and additively manufactured disc-shaped reflectors for sensitivity setting in ultrasonic testing

  • 期刊论文

  • 发表日期：

    2026年1月26日

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  • Maria Grozdanić,
  • Morana Mihaljević,
  • Damir Markučič

摘要

Reference reflectors are essential in ultrasonic testing (UT) for setting sensitivity and sizing flaws. Traditionally manufactured flat-bottom holes (FBHs) are well-established disc-shaped reflectors (DSRs) used for sensitivity setting of the UT system and sizing of detected flaws, but they are open to the surface. With the advent of additive manufacturing (AM), there is now a capability to fabricate alternative DSRs that can be embedded within components of finite thickness. This approach allows a closer resemblance to volumetric flaws. In this study, AM-produced DSRs are explored for UT sensitivity setting and flaw sizing, demonstrating their potential to overcome the limitations of traditional manufacturing methods that rely on drilling with flat-bottom drills. The DSRs in the AM blocks were designed in the CAD model and produced as fully integrated features during the direct metal laser sintering (DMLS) process. Two DMLS blocks were fabricated with varying layer thicknesses and reflector orientations, incorporating both embedded and surface-open reflectors. Their ultrasonic responses were compared to those from traditionally manufactured FBHs using the Distance-Gain-Size (DGS) technique. The study analysed A-scan echo patterns and equivalent reflector sizes (ERSs). Results show that AM-produced DSRs can provide ultrasonic responses similar to traditional FBHs with embedded reflectors, especially when aligned with the layer direction. These findings demonstrate the feasibility of using embedded AM-produced DSRs for UT sensitivity setting and flaw sizing in AM parts, thereby enabling tailored reference block design for non-destructive evaluation of both AM and traditionally manufactured parts.