non-destructive testing and advanced manufacturing

Advanced ManufacturingNon-Destructive Testing &

By: Hamed Malekmohammadi (Ph.D.)05.June.2020 NDTonAIR 8th (Last) Training Event

Outline

➢ Introduction to NDT and Quality Control

➢ Classification of NDT Methods

➢ Conventional, advanced and automated NDT

➢ Automated NDT

➢ Applications

➢ How advanced NDT saves cost and time?

➢ Bigger vision: from NDT to total asset management

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Part One

Quality Control and NDT

• Quality Control (QC): an aggregate of activities (such asdesign analysis and inspection for defects) designed toensure adequate quality especially in manufactured products(Merriam-Webster.com)

• Non-Destructive Testing (NDT): the process of inspecting, testing, or evaluating materials, components or assemblies for discontinuities, or differences in characteristics without destroying the serviceability of the part or system (ASNT.org)

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NDT Methods’ basic Classification (ASNT.com)

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Liquid Penetrant (PT)

Magnetic Particle (MT)

Radiography (RT)

Ultrasonic (UT)

Electromagnetic (ET)

Visual (VT)

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Guided Wave (GW)

Acoustic Emission (AE)

Laser Methods (LM)

Leak Testing (LT)

Magnetic Flux Leakage (MFL)

Neutron Radiography (NR)

Infrared Thermography (IR)

Vibration Analysis (VA)

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NDT Methods’ deep Classification

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Radiography (RT)

Ultrasonic (UT)

Visual (VT)

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Guided Wave (GW)


Laser Methods (LM)

Leak Testing (LT)





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Phased Array (PA)

TOFD

Immersion

Pulse-Echo

Through-Transm.

Conventional NDT

Automated UT

Advanced NDT





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Radiography (RT)

Ultrasonic (UT)


Visual (VT)

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Guided Wave (GW)


Laser Methods (LM)

Leak Testing (LT)





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CT

Computed RT

Analogue RT

Digital RT

Conventional NDTAdvanced NDT


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Radiography (RT)

Ultrasonic (UT)


Visual (VT)

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Guided Wave (GW)


Laser Methods (LM)

Leak Testing (LT)





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MW & THz

RFT

Eddy Current

ACFM

Conventional NDTAdvanced NDT

Conventional, Advanced and Automated NDT

• Conventional: basic NDT techniques havebeen in use as analog and now as digital,but they are conceptual methods of NDT,e.g. PT or RT

• Advanced: most recent developments in NDT techniques based on the concepts of conventional methods or are newly developed and independent, e.g. PA or IRT

• Automated: any of conventional or advanced NDT techniques, which have been automated (mechanized) by means of robotic or automation systems

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Automated NDT

• Automated NDT is a growing but matured approach in NDT• Decreases the time and costs• Increases the accuracy and speed• Interpretation can be done automatically• Less dependent on operator errors and skills• Suitable for production lines and continuous NDT tasks

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• Can be implemented for maintenancetasks as well

• Can consist of one or more NDT techniques

www.Google.com

NDT Applications

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NDT

Aerospace Oil and Gas Automotive InfrastructurePower

GenerationManufacturing

Iron and Steel

Shipbuilding

Pipe and Tube

Engine parts

Airframe

Composites

Maintenance

Pipelines

Storage Tanks

Pressure Equ.

LNG

Plants

Engine parts

Body and chassis

Composites

Bridges & Tunnels

Railway

Airport

Military and defense

Solar

Wind

Nuclear

Fossil fuel

Water

NDT Applications → Oil and Gas → 1st Case: Pipelines

• Every year thousands of km of pipelines

• Huge investment, money and time

• Costs: Engineering, Procurement, Construction

• Construction cost: mob-demob, personnel, logistics

• On- or off-shore: NDT in night shift →

• Goal: Down-time in installation shall be minimized

• Can improve other parts but NDT is 50% of time

• Offshore: no day/night shift but still significant time for NDT

• Main conventional NDT: RT, manual UT

• Radiation hazard, test time is long

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NDT Applications → Oil and Gas → 2nd Case: LNG tanks

• Construction problems are similar to pipelines• Construction time and costs are higher• Several NDT methods have to be used simultaneously• Down/waiting time due to NDT is high• LNG storage tanks:▪ Operating temperature: -163◦C▪ Materials:✓ Base metal:

9% Ni Steel (ASTM A553)✓ Welds:

Inconel and Hastelloy (Austenitic)• Austenitic welds →• Dissimilar grain structure• Difficult to test with both RT and UT

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NDT Applications → Oil and Gas → 2nd Case: LNG tanks

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Weld

Base

NDT Applications → Oil and Gas → What we are looking for?

• Typical weld defects

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NDT Applications → Oil and Gas → What are the solutions?

• Various advanced NDT are in the market: AUT, DRT

1st Generation: multi-probe AUT system

3rd Generation: 2D matrix Phased Array probe

Brand-new automatic X-Ray scanner

© ApplusRTD, Netherlands

NDT Applications → Oil and Gas → AUT Concepts

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NDT Applications → Oil and Gas → DRT Concepts

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sensor

source

Beam travels through 2 walls but due to high magnification of first wall only the second wall is sharply visible on screen.

DWSI = Double Wall Single Image

sensorsource

SWSI = Single Wall Single Image

Beam travels through only 1 wall; hence this wall is sharply visible on screen.

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2” to 12” range 6” – 56” range

NDT Applications → Oil and Gas → DRT Concepts

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Active area

• Rayscan uses a digital sensor (like adigital photocamera... but for xrays)

• The x-ray photographs are 6mm wideand up to 220mm long

• 300 photographs (or frames) a second!• Software re-constructs all photographs

to a complete weld-image

NDT Applications → Oil and Gas → Conventional vs. Advanced

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Automated X-Ray (RayScan®)


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Automated Ultrasonic (AUT for pipeline and tanks)

Bigger view → From NDT to asset management

• Structural Health Monitoring (SHM): diagnosis of thecurrent state of a structure, which consists of differentcomponents and materials. Structures undergo continuouschange caused by ageing processes, environmentalinfluences and also by unforeseen events e.g. earthquakes or(wind) buffeting

• Fitness for Service (FFS): is a best practice and standard usedby the oil & gas and chemical process industries for in-service equipment to determine its fitness forcontinued service

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• Risk Based Inspection (RBI): Optimal maintenance processto examine equipment in industrial plants. It examinesthe Health, Safety and Environment (HSE) and business riskof ‘active’ and ‘potential’ Damage Mechanisms (DMs) toassess and rank failure probability and consequence. Thisranking is used to optimize inspection intervals based onsite-acceptable risk levels and operating limits, whilemitigating risks as appropriate. It can be qualitative,quantitative or semi-quantitative in nature

• Asset Integrity Management (AIM): The ability of an asset toperform its required function effectively and efficientlyproviding value through optimum return on capitalinvestment, whilst safeguarding life and the environment

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Operations PhaseConstruction Phase

Asset Integrity Management

Asset Integrity

Operate:to Design Intent

Design Maintain

Fabrication & Construction

Commission

Integrated Inspection Engineering and NDT&I


⌂ Integrity management

→ Risk Based Inspection

→ Fitness for Service analysis

→ Degradation mechanism

→ Consequence of failure

→ Requirements, rules and regulations

→ NDT/SHM measurement locations

→ NDT/SHM method(s)

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Part Two

Outline

➢ Advanced manufacturing

➢ From Industry 1.0 to Industry 4.0

➢ Key advanced manufacturing techniques

➢ NDT in advanced manufacturing, NDT 1.0 to NDT 4.0

➢ Case study: Additive Manufacturing

➢ Challenges

➢ Summary and Prospect

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Part Two

Part Two

Advanced Manufacturing

• Manufacturing: act of converting raw materials to products bythe use of manual labour or machinery and that is usuallycarried out systematically with a division of labour. In a morelimited sense, manufacturing denotes the fabrication orassembly of components into finished products on a fairly largescale. (Britanica & Wikipedia)

• Advanced manufacturing: the use of innovative technologiesand methodologies for improved competitiveness in themanufacturing sectors →

▪ Quality controls▪ Lean production technologies▪ Supply chain integration▪ Advanced planning and scheduling

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Part Two

From Industry 1.0 to Industry 4.0

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Industry 1.0

• 18th century• Water- and steam-

powered machines• Mechanization

Industry 2.0

• 19th century• Electricity and assembly

line production• Mass production (Henry

Ford)

Industry 3.0

• 20th century (70’s)• Electronic devices, e.g.

transistor, integrated circuit chips

• Automation• PLC

Industry 4.0

• Information and communication technologies

• IOT• AR/VR

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Part Two

Advanced Manufacturing• Advanced Robotics and adaptive automation • Nano-technologies (materials and electronics)• Green and sustainable manufacturing (solar power, recycling)• Design and management of distributed supply chains (Cloud

computing for CAD/CAE/CAM)• Additive manufacturing (metals and plastics)• Composite manufacturing processes• Other processes:

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Process Example

Forming forging, rolling, extrusion, etc.

Moulding powder metallurgy, injection, etc.

Machining mill, lathe, etc.

Casting centrifugal, die, vacuum, etc.

Joining welding → LASER, ultrasonic, friction, etc.

Part Two

NDT and Advanced Manufacturing• Quality control a key feature in advanced manufacturing• To assure the quality →▪ Quality management system (e.g. ISO9001)▪ DT and NDT tools, inspection →✓ DT approach: sampling, offline✓ NDT approach: 100% control, online

Can be integrated to the manufacturing process

• Requirements →▪ Fast (real-time)▪ Reliable (stable and robust)▪ Automatic (no operator) ▪ Closed-loop (feedback to the manufacturing process)▪ Cost efficient▪ Comply with process

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Part Two

NDT 1.0 to NDT 4.0

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NDT 1.0

• Tools to enhance human senses

• Optical/visual mark• Impact (hammer)• Mic/stethocscope

NDT 2.0

• Electronics: devices• Surface to depth• Ultrasonics• X-ray, Gamma-ray• Magnetic

NDT 3.0

• Robotics• Automated NDT• Software tools• Image visualization• Computer algorithms

NDT 4.0

• Cloud-based• IOT• AR/VR• Wireless sensors• Sensor networks• Big data

NDT

Part Two

NDT 4.0 and Industry 4.0

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QualityProductivity

SafetySustainability

→In lifecycle of products

and assets

High precisionHarsh environments

DurabilitySmall size

Cost efficiency→

Guarantee the safe operation

Industry

4.0

Argumented RealityVirtual Reality

Embedded sensor systemsWireless/Network sensors

Cloud technology

Part Two

NDT 4.0 (Example)

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Part Two

Case Study: Additive Manufacturing (AM)• What is Additive manufacturing?▪ According to standard term (ASTM F2792), is defined as the

process of joining materials to make objects from 3D model data, usually layer upon layer, as opposed to subtractive manufacturing methodologies.

• What are AM applications?▪ Aerospace▪ Automotive▪ Healthcare▪ Product Development

• What are AM materials?▪ Thermoplastic▪ Metal▪ Ceramic▪ Biochemical

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Case Study: Additive Manufacturing → Processes

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Material extrusion

Directed Energy Deposition (DED)

Material extrusion

Material jetting

Binder jetting

Sheet lamination (LOM)

Vat polymerization

Powder Bed Fusion (PBF)

Direct Metal Laser Sintering (DMLS)

Selective Laser Sintering (SLS)

Selective Heat Sintering (SHS)

Electron Beam Melting (EBM)

Direct Metal Laser Melting (DMLM)

AM

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Case Study: Additive Manufacturing → How it works?

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Part Two

Case Study: Additive Manufacturing → Process Challenges *• Problems associated with AM processes:

1. Fast heating and cooling (~103–105 K/s) →▪ Suppressed phase transformations▪ Supersaturated phases▪ Segregation▪ Hot cracking▪ Thermal residual stresses

2. Unidirectional heat flow into substrate →▪ textured grains▪ anisotropic properties

3. Repeated heating and cooling cycles → temperatures can exceed Tα↔β → ▪ multiple phase transformations & complex microstructures▪ thermal residual stresses

* focused on metal-based AM

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Part Two

Case Study: Additive Manufacturing → Solutions

• Test and characterizations are necessary on- and off-line▪ Microscopy (e.g. SEM, TEM, EBSD, EELS)▪ Non-destructive Testing and Evaluations▪ Spectrometric techniques (e.g. GDOES)▪ Thermal techniques (e.g. DSC, DTA)▪ Hardness test (e.g. micro indentation)▪ Internal or surface attributes (eg. roughness)▪ Wear resistance▪ Fatigue, fracture and creep behavior

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Part Two

Case Study: Additive Manufacturing → Application of NDT

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In-situ

Off-line

Optical methods

X-Ray, XCT, ND,XBT

Infrared Thermography

Laser UltrasoundND

T in

AM

Ultrasound

EM techniques

High temp.

Complex Geometry

Part Two

Case Study: Additive Manufacturing → NDT Challenges

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AM Process

Decision making-

Feedback

In-situ NDTData

Acquisition

Post-processing

Big Data

Real-time processing

High speed

Material & process

Accuracy

Hazards

False calls

Part Two

NDT in Advanced manufacturing → Summary and prospect

• NDT is everywhere (onAIR, onART, underground, underwater, …)• Advanced manufacturing is growing fast and is finding

application in many areas of industry (e.g. AM, etc.)• There is a high demand for integration of QC/NDT solutions into

the production process• There are still challenges but new technologies will help• Advanced manufacturing and NDT can help promote each other

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Thanks for your attention!

Questions?

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And finally……

My sincere thanks goes to:

- Marco and Stefano for their unlimited support and

being a friend before being a colleague or supervisor;

- All ESRs; Abdoulaye, Akram, Bengisu, Houssem,

Jaishree, Khalid, Luca, Michael, Qiuji, Sergey, Sevilia,

Shaun, Silvio, Tommaso, Yongtak (Aadhik and Konrad)

for their valuable friendship and all I have learned from

them;

- All valued supervisors of NDTonAIR project for all they

taught us with passion and patience.

non-destructive testing and advanced manufacturing

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