advanced nde technologies for quality control
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Advanced NDE Technologies for Quality Control. November 9 th , 2012 Dr. Jeong Na Technology Leader NDE Group 1250 Arthur E. Adams Drive Columbus, OH 43221. Advacned NDE Technologies. Matrix Phased Array (MPA) Ultrasonics Laser Based Ultrasonics Array Eddy Current - PowerPoint PPT PresentationTRANSCRIPT
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Advanced NDE Technologies for Quality ControlNovember 9th, 2012
Dr. Jeong NaTechnology LeaderNDE Group1250 Arthur E. Adams DriveColumbus, OH 43221
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Advacned NDE Technologies
Matrix Phased Array (MPA) Ultrasonics
Laser Based Ultrasonics Array Eddy Current Ultrasonically Induced Thermography
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Linear Phased Array UT One-Dimensional Array Configuration Line Focusing, Steering and Electronic Scanning
Focusing Steering Scanning
PiezoElements
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Matrix Phased Array (MPA) Technology Provides 2-Dimensional Electronic Control of Beam:
Focusing, Steering, and Scanning
Each bar represents firing delay for each element
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3-D MPA Probe Convex Surface Contour No Requirement of Steering Less Number of Elements (8x8) Lower Frequency (12 MHz)
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Automotive Resistance Spot Welds Provides 2-D Image of Weld Nugget along with
Diameter and Area Information
6 mm RSW
ScreenShot
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Probability of Detection (POD) Nugget Size Ranged between 4 - 6 mm for Two 0.7 mm Sheets One Hundred Weld Samples Approximately 98% Accuracy in Sizing
Weld Nugget Diameter(0.7 mm Thickness)
0.0
2.0
4.0
6.0
8.0
10.0
0.0 2.0 4.0 6.0 8.0 10.0
Avg. Peel/Chisel Destructive Test Dia. (mm)
Avg.
UT
Dia
. (m
m)
UT vs Destructive
Ideal
95% LUS
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Laser Based Ultrasonics
• Non-contact• Fast Scan• Complex Geometries• Hostile Environments• High Spatial Resolution
• Versatile – Very small to Very Large Parts
1. Laser Generation2. Laser Detection3. Hardware, electronics, computers
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Elastic Waves
VL > VS > VRSound Velocity:
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Weld Joint Inspection
Levesque et.al. “Defect Detection and Residual Stress Measurement in Friction Stir Welds using Laser Ultrasonics”, LU 2008.
Butt Joint
Decreasing lack of penetration along weld
Weld Joint
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Mechanical Properties
Blouin et. al. “Detection of Skin Disbond in Honeycombs and Coating Detachment by Laser Tapping Technique”, LU 2008.
Honeycomb delamination and disbond
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Fundamentals of Eddy Current
Metallic Specimen
Drive Coil
EddyCurrent
Magnetic Flux Lines
.Metallic Specimen
Drive Coil
EddyCurrent
Magnetic Flux Lines
.
Crack
No Flaw With Flaw
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Array Eddy Current Technology
Spot A Spot B
32 Element Array Probe
Scanner
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Example - FSW Inspection
FSW
Friction Stir Welded Aluminum Plate (1” thick) 32 Element Flexible Eddy Current Probe (Multi
Frequency)
Scan Direction
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Inspection Results
20 kHz 480 kHz
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Ultrasonically Induced Thermography
UltrasonicHorn Temperature
MeasuringDevice
(IR or Optical)TestSpecimen
AcousticEnergy
• Fast and Non-Contact Inspection• Easy to Interpret Inspection Results
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Ultrasonic Induced Thermography
Through Transmission Measurement Single Side Measurement
Ultrasonic Horn
Temperature Sensor
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Example (Resistance Spot Welded Thin Metal Plates)
Good WeldBad Weld
X-ray image showing weld nuggets(2 mm diameter RSW)
0
1
2
3
4
5
0 5000 1 104 1.5 104
Good WeldBad Weld
Cha
nge
in T
empe
ratu
re (o C
)
Time (ms)
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Correlation to Pull Strength
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Summary
Wide range of inspection applications with matrix phased array technology with accuracy and reliability
Laser based ultrasonics is getting widely used across the board as a fast non-contact inspection tool
Imaging capability of array eddy current can reduce operator dependency with easy to understand inspection results
Non-contact ultrasonically induced thermography technique makes it possible to develop a high speed automated inspection system for weld quality as well as bond quality
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