Study of Online Testing of Void Defects in AM Components with Grating Laser Ultrasonic Spectrum Method

Void defects, manifested as distributed porosity, are common in metal additive manufacturing (AM) and can significantly degrade the mechanical performance and reliability of fabricated components. To enable real-time quality control during fabrication, this study proposes a grating laser ultrasonic method for the online evaluation of porosity in AM parts. Based on the theoretical relationship between surface acoustic wave (SAW) velocity and material porosity, a non-contact detection approach is developed, allowing the direct inference of porosity from the measured SAW velocities without requiring knowledge of the exact source–detector distance. Numerical simulations are conducted to analyze SAW propagation under varying porosity conditions and to validate the inversion model. Experimental measurements on aluminum alloy specimens with different porosity levels further confirm the sensitivity of SAW signals to internal voids. The results show consistent waveform and spectral trends between the simulation and experiment, supporting the feasibility of the proposed method for practical applications. Overall, the findings demonstrate the potential of this approach for the accurate online monitoring of void defects in metal AM components.