A Review of Non-Destructive Testing (NDT) Techniques for Defect Detection: Application to Fusion Welding and Future Wire Arc Additive Manufacturing Processes

In Wire and Arc Additive Manufacturing (WAAM) and fusion welding, various defects such as porosity, cracks, deformation and lack of fusion can occur during the fabrication process. These have a strong impact on the mechanical properties and can also lead to failure of the manufactured parts during service. These defects can be recognized using non-destructive testing (NDT) methods so that the examined workpiece is not harmed. This paper provides a comprehensive overview of various NDT techniques for WAAM and fusion welding, including laser-ultrasonic, acoustic emission with an airborne optical microphone, optical emission spectroscopy, laser-induced breakdown spectroscopy, laser opto-ultrasonic dual detection, thermography and also in-process defect detection via weld current monitoring with an oscilloscope. In addition, the novel research conducted, its operating principle and the equipment required to perform these techniques are presented. The minimum defect size that can be identified via NDT methods has been obtained from previous academic research or from tests carried out by companies. The use of these techniques in WAAM and fusion welding applications makes it possible to detect defects and to take a step towards the production of high-quality final components.