Iranian Journal of Manufacturing Engineering

Iranian Journal of Manufacturing Engineering

Using wavelet transform and vibration mode shapes to identify crack defect in additively manufactured steel plate

Document Type : Original Article

Authors
Ali Reza Mirmohamadkhani
Reza Azarafza
Reza shoja razavi
Masood Barkat
Faculty of Materials and Manufacturing Technologies, Malek Ashtar University of Technology, Tehran, Iran
10.22034/ijme.2025.532775.2101
Abstract
Cracks in additive manufacturing parts, such as those produced by laser selective melting, are common defects. Modal testing is a non-destructive method used to detect such defects. However, the small size of cracks and the limited dimensions of parts made by this technique present challenges, including difficulties in exciting high-frequency modes. This study demonstrates that modal-based diagnostic methods alone cannot effectively identify small cracks. In contrast, a combined approach using wavelet transform and mode shape analysis can detect cracks with small depths. In this research, cracks with varying depths were intentionally introduced on an additively manufactured plate, and the integrated method was applied for defect identification. Results showed that mode shape analysis alone could detect cracks with an intensity of 30%, while combining it with wavelet transform improved detection sensitivity to cracks with as low as 10% intensity. According to the findings, the combined wavelet transform method can detect and locate cracks with 10% intensity with an error margin of 4% in numerical modal analysis and 10% in experimental modal testing. Another result indicates that modeling the plate as a rigid body without considering layer effects is reasonable due to the production nature and powder type, yielding results close to experimental tests. In summary, this research highlights that utilizing modal diagnostic methods for additive manufacturing parts is a practical inspection approach, and further development of these methods is essential for such components.
Keywords
Additive Manufacturing
Selective Laser Melting
Modal Defect Detection
Vibration Mode Shapes
Wavelet Transform
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