Portable through-metal ultrasonic power transfer using a dry-coupled detachable transmitter.

Ultrasonic waves can be used to transfer power and data efficiently through metallic enclosures when feedthroughs are not practical due to structural or electromagnetic shielding considerations. Previous implementations of ultrasonic power transfer (UPT) used a piezoelectric transducer permanently bonded to the metal for efficient ultrasonic coupling. For portable operation, it is essential to have a detachable transmitter (charger) that is only attached to the enclosure while transferring power. This requirement presents several design challenges; notably, detachable ultrasonic coupling typically relies on liquid or gel couplant, which may become inconvenient or less robust during repeated attachment and detachment. Thus, this work develops a dry-coupled detachable UPT system to transfer power efficiently through a metallic enclosure without the need for a liquid couplant. Low attenuation soft elastomers are experimentally tested with a magnetic setup to evaluate their dry-coupled efficiency. Samples with different materials and thicknesses are experimentally tested to select the best configuration for dry ultrasonic coupling. The softest elastomer tested yielded the best ultrasonic efficiency (AC-to-AC) of 68% at 1 MHz. A full DC-to-DC portable (battery-operated) UPT system was then developed and experimentally characterized. The system was capable of delivering up to 3 W of DC power to a resistive load with a total efficiency of 50%.

Ultrasonic testing of thick and thin Inconel 625 alloys manufactured by laser powder bed fusion.

Additive manufacturing of alloys enables low-volume production of functional metallic components with complex geometries. Ultrasonic testing can ensure the quality of these components and detect typical defects generated during laser powder bed fusion (LPBF). However, it is difficult to find a single ultrasonic inspection technique that can detect defects in the large variety of geometries generated using LPBF. In this work, phased array ultrasonic testing (PAUT) is suggested to inspect thick LPBF components, while guided waves are explored for thin curved ones. PAUT is used to detect cylindrical lack of fusion defects in thick LPBF rectangular parts. Practical defects are generated by reducing the laser power at prespecified locations in the samples. The defects' shape and density are verified using optical microscopy and X-ray computed tomography. Partially fused defects down to 0.25 mm in diameter are experimentally detected using a 10 MHz PAUT probe with the total focusing method post-processing. The experimental results are compared to defect images predicted by finite element simulations. For thin components with curved geometry, guided waves are used to detect powder-filled cylindrical defects. The waves are generated using piezoelectric transducers, and the spatiotemporal wavefield is measured using a scanning laser Doppler vibrometer. Using root-mean-square imaging of the wavefield, defects down to 1 mm are clearly detected despite the complex internal features in the samples.