Orientation imaging of macro-sized polysilicon grains on wafers using spatially resolved acoustic spectroscopy

Due to its economical production process polysilicon, or multicrystalline silicon, is widely used to produce solar cell wafers. However, the conversion efficiencies are often lower than equivalent monocrystalline or thin film cells, with the structure and orientation of the silicon grains strongly linked to the efficiency. We present a non-destructive laser ultrasonic inspection technique, capable of characterising large (52 x 76 mm2) photocell's microstructure – measurement times, sample surface preparation and system upgrades for silicon scanning are discussed. This system, known as spatially resolved acoustic spectroscopy (SRAS) could be used to optimise the polysilicon wafer production process and potentially improve efficiency

Spatially resolved acoustic spectroscopy for selective laser melting

Additive manufacturing (AM) is a manufacturing technique that typically builds parts layer by layer, for example, in the case of selective laser melted (SLM) material by fusing layers of metal powder. This allows the construction of complex geometry parts, which, in some cases cannot be made by traditional manufacturing routes. Complex parts can be difficult to inspect for material conformity and defects which are limiting widespread adoption especially in high performance arenas. Spatially resolved acoustic spectroscopy (SRAS) is a technique for material characterisation based on robustly measuring the surface acoustic wave velocity. Here the SRAS technique is applied to prepare additively manufactured material to measure the material properties and identify defects. Results are presented tracking the increase in the measured velocity with the build power of the selective laser melting machine. Surface and subsurface defect measurements (to a depth of ∼24 μm) are compared to electron microscopy and X-ray computed tomography. It has been found that pore size remains the same for 140 W to 190 W melting power (mean: 115–119 μm optical and 134–137 μm velocity) but the number of pores increase significantly (70–126 optical, 95–182 velocity) with lower melting power, reducing overall material density

Assessing the capability of in-situ nondestructive analysis during layer based additive manufacture

Unlike more established subtractive or constant volume manufacturing technologies, additive manufacturing methods suffer from a lack of in-situ monitoring methodologies which can provide informationrelating to process performance and the formation of defects. In-process evaluation for additive manufacturing is becoming increasingly important in order to assure the integrity of parts produced in this way. This paper addresses the generic performance of inspection methods suitable for additive manufacturing. Key process and measurement parameters are explored and the impacts these have upon production rates are defined. Essential working parameters are highlighted, within which the spatial opportunity and temporal penalty for measurement allow for comparison of the suitability of different nondestructive evaluation techniques. A new method of benchmarking in-situ inspection instruments and characterising their suitability for additive manufacturing processes is presented to act as a design tool to accommodate end user requirements. Two inspection examples are presented: spatially resolved acoustic spectroscopy and optical coherence tomography for scanning selective laser melting and selective laser sintering parts, respectively. Observations made from the analyses presented show that the spatial capability arising from scanning parameters affects the temporal penalty and hence impact upon production rates. A case study, created from simulated data, has been used to outline the spatial performance of a generic nondestructive evaluation method and to show how a decrease in data capture resolution reduces the accuracy of measurement

Meso-scale defect evaluation of selective laser melting using spatially resolved acoustic spectroscopy

Developments in additive manufacturing technology are serving to expand the potential applications. Critical developments are required in the supporting areas of measurement and in process inspection to achieve this. CM247LC is a nickel superalloy that is of interest for use in aerospace and civil power plants. However, it is difficult to process via selective laser melting (SLM) as it suffers from cracking during rapid cooling and solidification. This limits the viability of CM247LC parts created using SLM. To quantify part integrity, spatially resolved acoustic spectroscopy (SRAS) has been identified as a viable non-destructive evaluation technique. In this study, a combination of optical microscopy and SRAS was used to identify and classify the surface defects present in SLM-produced parts. By analysing the datasets and scan trajectories, it is possible to correlate morphological information with process parameters. Image processing was used to quantify porosity and cracking for bulk density measurement. Analysis of surface acoustic wave data showed that an error in manufacture in the form of an overscan occurred. Comparing areas affected by overscan with a bulk material, a change in defect density from 1.17% in the bulk material to 5.32% in the overscan regions was observed, highlighting the need to reduce overscan areas in manufacture

Determining the crystallographic orientation of hexagonal crystal structure materials with surface acoustic wave velocity measurements

© 2020 Throughout our engineered environment, many materials exhibit a crystalline lattice structure. The orientation of such lattices is crucial in determining functional properties of these structures, including elasticity and magnetism. Hence, tools for determining orientation are highly sought after. Surface acoustic wave velocities in multiple directions can not only highlight the microstructure contrast, but also determine the crystallographic orientation by comparison to a pre-calculated velocity model. This approach has been widely used for the recovery of orientation in cubic materials, with accurate results. However, there is a demand to probe the microstructure in anisotropic crystals - such as hexagonal close packed titanium. Uniquely, hexagonal structure materials exhibit transverse isotropic linear elasticity. In this work, both experimental and simulation results are used to study the discrete effects of both experimental parameters and varying lattice anisotropy across the orientation space, on orientation determination accuracy. Results summarise the theoretical and practical limits of hexagonal orientation determination by linear SAW measurements. Experimental results from a polycrystalline titanium specimen, obtained by electron back scatter diffraction and spatially resolved acoustic spectroscopy show good agreement (errors of ϕ1=5.14° and Φ=6.99°). Experimental errors are in accordance with those suggested by simulation, according to the experimental parameters. Further experimental results demonstrate dramatically improved orientation results (Φ erro

Single pixel camera methodologies for spatially resolved acoustic spectroscopy

Spatially resolved acoustic spectroscopy (SRAS) is a laser ultrasound technique used to determine the crystallographic orientation (i.e. microstructure) of materials through the generation and measurement of surface acoustic wave velocity on a sample. Previous implementations have used a grating pattern imaged onto the surface to control the frequency of the generated wave in a single direction-grain orientation can be computed by acquiring wave velocities in different directions on the surface (gathered by physically rotating the grating pattern). This paper reports an advance to this methodology, inspired by single pixel cameras, using a coded grating pattern, created using a spatial light modulator, to excite surface acoustic waves in multiple directions simultaneously. This change to the optical arrangement can simplify the overall system alignment, remove mechanical complexities and is well suited for point-by-point full orientation imaging, potentially allowing for faster orientation imaging using SRAS microscopy. Improvements to the robustness of measurement may be expected to extend the applicability of SRAS in the material science field. To demonstrate this methodology, experiments were conducted on isotropic and anisotropic samples

Spatially resolved acoustic spectroscopy for texture imaging in powder bed fusion nickel superalloys

© 2019 Author(s). There is a clear industrial pull to fabricate high value components using premium high temperature aerospace materials by additive manufacturing. Inconveniently, the same material properties which allow them to perform well in service render them difficult to process via powder bed fusion. Current build systems are charac-terised by high defect rates and erratic microstructure, leading to components with inferior mechanical properties. The work presents microstructural texture imaging of powder-bed fusion components by a non-contact laser ultrasonic method, Spatially Resolved Acoustic Spectroscopy (SRAS). In short, this work demonstrates the ability to SRAS to detect and characterise meso-scale crystalline texture features. Probing samples manufactured by powder bed fusion, in the common nickel based aerospace superalloy Inconel 718, it has been shown the the primary crystalline orientation of can be inferred from the measured velocity, with good agreement with Electron Backscatter Diffraction. The studied sample was found to have a microstructure formation that bore a heavy resemblance to the chosen scanning pattern, with clear influence from the geometry through varying scan vector length and island-boundary scan strategy. This work forms part of a progression towards deployment of a SRAS system as an in-situ inspection solution for PBF

Assessing the capability of in-situ nondestructive analysis during layer based additive manufacture

Unlike more established subtractive or constant volume manufacturing technologies, additive manufacturing methods suffer from a lack of in-situ monitoring methodologies which can provide informationrelating to process performance and the formation of defects. In-process evaluation for additive manufacturing is becoming increasingly important in order to assure the integrity of parts produced in this way. This paper addresses the generic performance of inspection methods suitable for additive manufacturing. Key process and measurement parameters are explored and the impacts these have upon production rates are defined. Essential working parameters are highlighted, within which the spatial opportunity and temporal penalty for measurement allow for comparison of the suitability of different nondestructive evaluation techniques. A new method of benchmarking in-situ inspection instruments and characterising their suitability for additive manufacturing processes is presented to act as a design tool to accommodate end user requirements. Two inspection examples are presented: spatially resolved acoustic spectroscopy and optical coherence tomography for scanning selective laser melting and selective laser sintering parts, respectively. Observations made from the analyses presented show that the spatial capability arising from scanning parameters affects the temporal penalty and hence impact upon production rates. A case study, created from simulated data, has been used to outline the spatial performance of a generic nondestructive evaluation method and to show how a decrease in data capture resolution reduces the accuracy of measurement

Spatially resolved acoustic spectroscopy for rapid imaging of material microstructure and grain orientation

Measuring the grain structure of aerospace materials is very important to understand their mechanical properties and in-service performance. Spatially resolved acoustic spectroscopy is an acoustic technique utilizing surface acoustic waves to map the grain structure of a material. When combined with measurements in multiple acoustic propagation directions, the grain orientation can be obtained by fitting the velocity surface to a model. The new instrument presented here can take thousands of acoustic velocity measurements per second. The spatial and velocity resolution can be adjusted by simple modification to the system; this is discussed in detail by comparison of theoretical expectations with experimental data