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Abstract: Directed energy deposition (DED) is a promising additive manufacturing technique for repair; however, DED is prone to surface waviness (humping) in thin-walled sections, which increases residual stresses and crack susceptibility, and lowers fatigue performance. Currently, the crack formation mechanism in DED is not well understood due to a lack of operando monitoring methods with high spatiotemporal resolution. Here, we use inline coherent imaging (ICI) to optically monitor surface topology and detect cracking in situ, coupled with synchrotron X-ray imaging for observing sub-surface crack healing and growth. For the first time, ICI was aligned off-axis (24° relative to laser), enabling integration into a DED machine with no alterations to the laser delivery optics. We achieved accurate registration laterally (<10 µm) and in depth (<3 µm) between ICI measurements and the laser beam position using a single-element MEMS scanner and a custom calibration plate. ICI surface topology is verified with corresponding radiographs (correlation >0.93), directly tracking surface roughness and waviness. We intentionally seed humping into thin-wall builds of nickel super-alloy CM247LC, locally inducing cracking in surface valleys. Crack openings as small as 7 µm were observed in situ using ICI, including sub-surface signal. By quantifying both humping and cracking, we demonstrate that ICI is a viable tool for in situ crack detection.

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Abstract: Deformation bands, or tabular zones of localised strain, are a common manifestation of deformation in upper crustal sedimentary rocks. Any mining or energy-related engineering applications must consider the possibility of reactivating these pre-existing failure planes because doing so can cause seismicity and compartmentalise the reservoir. However, there has only been a small amount of research done on laboratory-induced deformation in rocks with natural deformation features. On a low porosity bioclastic calcarenite from the Cotiella Basin, Spanish Pyrenees, our current experimental work aims to capture, for the first time to our knowledge, the dominant failure mechanisms during the reactivation of natural deformation bands oriented at different angles to the principal stress direction. At the I12-JEEP beamline at the synchrotron facility of Diamond Light Source, UK, we carried out triaxial compression experiments using a modified version of the Mjolnir cell used by Cartwright-Taylor et al., (2022) to examine how these highly heterogeneous rocks respond to additional mechanical deformation. During the deformation experiments, 4D (time and space) x-ray tomography images (8 m voxel size resolution) were acquired. We tested confining pressures between 10 MPa and 30 MPa. The mechanical data demonstrate that the existence of natural deformation features within the tested samples weakens the material. For instance, solid samples of the host rock subjected to the same confining pressures had higher peak differential stresses. Additionally, our findings demonstrate that new deformation bands form as their angle, θ, to σ1 increases, while the reactivation of pre-exiting deformation bands in this low porosity carbonate only occurs for dipping angles close to 70o. The spatio-temporal relationships between the naturally occurring and laboratory-induced deformation bands and fractures were investigated using time-resolved x-ray tomography and Digital Volume Correlation (DVC). Volumetric and shear strain fields were calculated using the SPAM software (Stamati et al., 2020). The orientation of the recently formed failure planes is influenced by the orientation of the pre-existing bands, as well as their width and the presence (or absence) of porosity along their length. Additionally, pre-existing secondary deformation features found in the tested material trigger additional mechanical damage that either promotes the development or deflects the new failure planes.

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Abstract: X-ray phase-contrast tomography (X-PCT) techniques are capable of imaging samples with small differences in densities. They enable scientists to study biological or medical samples using high energy X-rays, which means less X-ray absorption and less sample damage, with high contrast quality. One branch of these techniques known as speckle-based methods have been well developed and demonstrated on real applications by different groups of developers using their own codes. However, there is lack of collective effort to package these methods into an open-source software which is easy-to-install, easy-to-use, well-documented, and optimized for speed. Such software is crucial to make the X-PCT techniques accessible to generic users and become regular tools. This report demonstrates the effort which implements speckle-based phase-retrieval methods in Python and GPU.

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Abstract: Neutron and X-ray tomography (NCT and XCT, respectively) are imaging techniques increasingly being applied in geomechanics research. They are used to non-destructively reveal different microstructural aspects of geomaterials: XCT is often used to observe/quantify differences in density or porosity, while NCT reveals the presence and distribution of hydrogenous materials such as water. The correlated use of NCT and XCT for geomechanics and geotechnics research is in its infancy. To this date, very few experiments have been carried out that combine both techniques, and none have been used to investigate geomaterial-structure interaction. This paper presents the first correlative NCT-XCT imaging study of pile installation. A scaled model pile was installed in an unsaturated intact chalk cylinder and in-situ NCT and ex-situ XCT synchrotron-based imaging was applied consecutively. Chalk was used because the behaviour of displacement piles installed in this material is still subject to considerable uncertainty. Results reveal for the first time the interaction between installation-induced changes in chalk density and water distribution variations, with evidence of water displacement into the densified material in the vicinity of the installed pile. A straightforward method for correlative bulk density-moisture content determination from NCT-XCT images of geomaterials are presented and their limitations discussed.

Open Access

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Abstract: X-ray computed tomography (XCT) is regularly employed in geomechanics to non-destructively measure the solid and pore fractions of soil and rock from reconstructed 3D images. With the increasing availability of high-resolution XCT imaging systems, researchers now seek to measure microfabric parameters such as the number and area of interparticle contacts, which can then be used to inform soil behaviour modelling techniques. However, recent research has evidenced that conventional image processing methods consistently overestimate the number and area of interparticle contacts, mainly due to acquisition-driven image artefacts. The present study seeks to address this issue by systematically assessing the role of XCT acquisition parameters in the accurate detection of interparticle contacts. To this end, synchrotron XCT has been applied to a hexagonal close-packed arrangement of glass pellets with and without a prescribed separation between lattice layers. Different values for the number of projections, exposure time, and rotation range have been evaluated. Conventional global grey value thresholding and novel U-Net segmentation methods have been assessed, followed by local refinements at the presumptive contacts, as per recently proposed contact detection routines. The effect of the different acquisition set-ups and segmentation techniques on contact detection performance is presented and discussed, and optimised workflows are proposed.