ASNT 2020: The Annual Conference

Evaluation of In-Motion Hi-Rail Mounted ECHO-Rail RCD Measurement System

Presenting author(s): Dr Anish Poudel

Co-Authors: Dr Matthew Witte

Room: Virtual Room | 10:00 AM Tuesday, November 10, 2020

Rolling Contact Damage (RCD) of the rails and wheels is a perennial problem for railroads around the world and poses a significant burden on track maintenance. RCD in rail is primarily a result of the interaction of railway wheels with the railhead and can reduce wheel and rail service life. Small cracks can appear on the running surface of the rails. These small cracks can ultimately grow and join up to form a flake that falls loose, leaving behind a cavity in the running surface of the rail; or they can turn downward to a limited depth forming a fatigue crack under the rail surface. Small cracks are commonly referred to as head checks and gauge-corner cracks. Non-destructive evaluation (NDE) technologies that can perform an accurate and efficient assessment of rail surface cracking while remaining insensitive to flaking and spalling are sought. The ideal NDE technology for RCD characterization would be non-contact, real-time, and in-motion capable.

This paper discusses the development of the in-motion hi-rail mounted ECHO-Rail shaped sensor/ECHO-Rail RCD measurement system and evaluation of these at higher speeds up to 20 mph on the test track. The shaped sensor acquired data from the running surface and gage corner of the rail in a single pass. Post-processing ECHO-Rail software also was developed for real-time data analysis. Field testing was conducted on the Rail Defect Test Facility (RDTF) and High Tonnage Loop (HTL) located at Transportation Technology Center (TTC) near Pueblo, CO, with tests designed to correlate the ECHO-Rail scan measurements to actual RCD defect depths.

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Air-Coupled Ultrasonic Testing and Digital X-Ray Imaging – Increasing the Probability of Detection by Combining Complementary NDT Methods in a Modern Dual Robot Setup

Presenting author(s): Mr Tobias Gautzsch

Co-Authors: Mr Josef Uher, Mr Manuel Lucas, Mr Mohamed Ghita, Mr Andreas Bodi

Room: Virtual Room | 10:00 AM Tuesday, November 10, 2020

Air-Coupled Ultrasonic Testing (ACUT) and digital X-Ray-Imaging are widely considered to be competitive methods for nondestructive testing. Convinced of the complementarity of these techniques, Radalytica a.s. and SONOTEC GmbH collaborated to combine digital X-Ray imaging with Air-Coupled Ultrasonic Testing in a dual robot inspection system. In the resulting feasibility study a variety of samples was tested with both methods. An analysis of the similarities and differences in the inspection results demonstrated the advantages that a combination of both technologies in one system could offer for automated inspection of lightweight materials. The inspection system uses a setup with two cooperative robots (cobots) which are facing each other. A special software was developed to combine the precise motion of each robot around a shared tool center point with the easy scan plane setup needed for quick non-destructive testing. Combined with an optimized calibration procedure, the cobots allow mobility, a fast setup and short inspection times in the field as well as in the laboratory. During the feasibility study a variety of aerospace composite samples were inspected with x-ray and air-coupled ultrasound. Through known defects, the detectability and sizing of various flaws including delamination, impact damage, dry or broken fibers and kissing bonds was evaluated and compared. The inspection capability for honeycomb and foam core sandwich structures was determined on aerospace style reference samples. The study concludes with a critical analysis of commonly used methods to implement test flaws and their effect on the test results of NDT methods.

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Eddy Current Rail Testing – Realizing Its Potential

Presenting author(s): Dr Scott Saunders

Co-Authors:

Room: Virtual Room | 10:30 AM Tuesday, November 10, 2020

The use of the eddy current method to test railway tracks has been gaining considerable popularity in the last decade. It looks likely to become the standard method to test the surface of rail for cracks caused by rolling contact fatigue. Recent work by Sperry Rail has shown that in addition to testing stock rail for gauge corner cracking, eddy current testing can be employed to locate cracks in switches and crossings and can find a variety of other surface defects. In addition, by identifying the location of rail features such as welds and rail ends, eddy current data can assist in accurately determining the position of the test vehicle in the network and can assist in the verification of defects. This presentation will illustrate how eddy current testing can be applied throughout a railway network on any track that is accessible by a railway wheel. Examples of damage found in traditionally untestable regions will be shown along with responses to a range of surface defects. Efforts to use machine learning to locate rail features will be outlined and some potential applications discussed.

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Characterization of Damage in Polymer Matrix Composites by Analyzing Polymer-Moisture Interactions

Presenting author(s): Mr Ogheneovo Idolor

Co-Authors:

Room: Virtual Room | 10:30 AM Tuesday, November 10, 2020

New, simple, and reliable non-destructive examination methods are required to encourage mainstream adoption of polymer matrix composites as safety-critical structures. Polymer matrix composites have a tendency to absorb moisture from their operating environment. This absorbed moisture interacts with the polymer matrix in one of two ways: either becoming bound to the polymer network (‘bound’ water), or existing within voids with no polymer-water interactions, remaining as ‘free’ water. Damage in the form of micro-cracks and delaminations creates internal voids which act as sites for free water molecules to form clusters. In this study, the potential for leveraging this distinct feature in damage characterization is investigated. Experiments involved 3 and 5 joule central impact on typical aerospace epoxy/glass fiber 16-ply composite laminates, causing barely discernible damage. Immediately after impact, pristine and damaged specimens are immersed in deionized water to accelerate moisture absorption, simulating long term moisture exposure. Changes in the nature of molecular water interaction with the polymer were characterized periodically by employing near-infrared spectroscopy to measure changes in free to bound water ratios, and a split post dielectric resonator to measure changes in microwave frequency relative permittivity. Both methods are proven to show sensitivity and distinct responses to free and bound moisture. Results show a direct correlation between the extent of damage and both the ratio of free to bound water and relative permittivity at a fixed moisture content. Results from both methods are indicative of relatively higher levels of free water at damage sites compared to undamaged sites where the majority of moisture exists in the bound state, resulting from interactions with polar sites. Therefore, by analyzing the nature of interaction between absorbed moisture and the polymer matrix, a method for localized damage detection can be developed.

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Railcar Wheels Sub-surface Defect Monitoring Using Ultrasonics

Presenting author(s): Mr Brian K Lindeman

Co-Authors: Dr Anish Poudel, Dr Matthew Witte

Room: Virtual Room | 11:30 AM Tuesday, November 10, 2020

Broken wheels are frequently associated with cracks caused by the phenomena of metallic fatigue. These wheels typically exhibit signs of damage at or near the edge of the tread on the field side of the wheel. Ultrasonic nondestructive evaluation (NDE) is useful for detecting these internal defects, but hand scanning of the millions of wheels in service is prohibitive. Transportation Technology Center Inc. (TTCI) sponsored by the Association of American Railroads (AAR) has researched, helped develop, and tested an automated cracked wheel detection system (ACWDS) capable of inspecting wheels on moving trains. The system implements arrays of spring-loaded ultrasonic probes aligned within a segment of a special track. Validation of the system was performed using the heavy axle load (HAL) test train (consist of about 120 cars; each car weighs 39-ton axle load) at Transportation Technology Center (TTC). This train operates nightly at the high tonnage loop (HTL) located at the facility for accelerated service testing (FAST), TTC near Pueblo, CO, and accumulates service wear at a rapid rate. Bi-weekly inspections using the ACWDS regularly find wheel defects that are not currently condemnable according to AAR standards. Once the wheels are alarmed by the ACWDS, conventional hand-UT tests were conducted to confirm the ACWDS findings which are in close agreements. Some of these wheels were tracked over time to gain insight into crack growth rates. Others were removed if deemed a safety risk to operations. As such, system performance is validated with the detection of otherwise unknown defects in the FAST train wheels.

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Analysis of Ballistic Impacts on Composite Materials by Infrared Active Thermography

Presenting author(s): Mr Stephane Boubanga

Co-Authors: Mr Vince Morton, Mr Wes Autran, Mr Benjamin Saute

Room: Virtual Room | 11:30 AM Tuesday, November 10, 2020

Since the beginning of the last century the ongoing advances in materials engineering have led to an unrestrained development of new technologies. Composite materials are the ones attracting most attention because they have many advantages over their homogeneous counterparts. These include high specific stiffness and high specific strength combined with a significant reduction in weight making them attractive for many industrial applications. One of the most important fields of application is the defense industry were the composites properties such as low weight, rigidity, strength and durability are of key importance. Composite materials made from artificially obtained high strength fibers are particularly interesting. These composites are characterized by many fiber-reinforced properties that make them ideal for ballistic protection applications. The ballistic protection equipment should protect the user from for instance arms fire. The proper analysis strategy of the area of internal damage caused by the impact of bullets is very important in the research and evaluation of protective composite ballistic equipment. Damage to the internal structure of the composite coating material can only be assessed using non-destructive testing methods. Such methods, such as infrared thermography test methods, are particularly effective in the case of composite materials. This work focused on the assessment of the damaged area on composites ballistic plates subjected to high velocity impact. Active pulsed thermography technique was used for performing post-mortem analysis of the impacted specimens. The post-mortem analysis was combined with inputs of the velocity of the projectile, the absorbed energy to evaluate how efficient the material is at spreading the absorbed energy to a large area. When sample is impacted by the projectile, at the moment of impact the projectile is slowed by a large number of individual fibers. As a result of the impact, fibers in the sample stretch and break to absorb the kinetic energy of the projectile casing. This creates a subsurface defect in the composite structure with a much greater area than the caliber of the projectile. We showed in this work that it is possible to assess the degree of destruction of the internal material as more damaged areas generate more heat, and over these areas, the surficial temperature signal has a higher value. We also demonstrated the benefits of using high speed infrared camera for energy measurement to the characterization of ballistic material are numerous. The most obvious of them is it’s allowing the user to see beyond the visible deformation limit the real surface area affected by a ballistic impact. Heat is generated not only by the plastic mechanical deformation but also by the stress induced by the impact. These thermodynamic behaviors are easily captured by the high-speed infrared camera.

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TBD- Railroads

Presenting author(s):

Co-Authors:

Room: Virtual Room | 12:00 PM Tuesday, November 10, 2020

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Neutron CT Basics and Advancements

Presenting author(s): Mr Muhammad Abir

Co-Authors:

Room: Virtual Room | 12:00 PM Tuesday, November 10, 2020

In general, X-ray radiography produces a two-dimensional projection of a three-dimensional object. X-ray computed tomography (CT) is commonly used in nondestructive testing to obtain the three-dimensional structure of an object. By taking a series of X-ray projection images at different angular views, a mathematical algorithm reconstruct the 3D structure of the object. However, X-rays interact linearly with the atomic number of materials and cannot provide adequate contrast in low Z material or isotopes. Neutrons interact with the nuclei of the material and can interact differently with different isotopes. Hence, neutron imaging is an important tool for imaging objects and detecting discontinuities that are not easily detectable using X-ray imaging. Madison-based nuclear technology company Phoenix LLC is investigating neutron radiography and tomography as the next landmark innovation in the rapidly advancing field of neutron radiography.

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Defect detection on rail base area using Infrared Thermography

Presenting author(s): Mr Survesh Shrestha

Co-Authors:

Room: Virtual Room | 12:30 PM Tuesday, November 10, 2020

Rail base defects (due to fatigue and corrosion) are difficult to detect, and currently there are no reliable or practical non-destructive evaluation (NDE) methods for finding these types of defects in the revenue service. This paper focuses on determining the capabilities of flash infrared thermography (IRT) for the detection of common rail base defects. Results from transient thermal finite element analysis (FEA) of rail models with such defects showed that this method can detect surface breaking and near surface rail base defects with reasonable thermal contrast of up to approximately 2°C in defective areas depending on the geometry and location of the defect. Rail samples used in this research contained base fractures from edge cuts, side-drilled and bottom-drilled holes. Additionally, preliminary IRT inspections were performed on low carbon steel samples of thicknesses 0.37 and 0.5 inch for better understanding the heat transfer behavior in metals. These samples contained drilled holes of varying orientations, sizes and subsurface depths. The holes in the steel samples were detected in the raw image sequence obtained from flash IRT. Furthermore, the resulting images were enhanced using Thermographic Signal Reconstruction (TSR).

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Looking Forward: Reviving Training and Certification for Neutron Radiography

Presenting author(s): Mr Michael J Taylor »

Co-Authors:

Room: Virtual Room | 12:30 PM Tuesday, November 10, 2020

Neutron radiography is an NDT method that dates back to the early 1950’s. Akin to X-Ray inspection, neutron radiation provides a means to visualize and quantify sensitivity, contrast, noise, and uniformity, and allows the interpreter to obtain information about foreign materials, cracks, voids, and delaminations that are not visible using any other NDT method. Neutron inspection has the unique ability to visualize specific materials, such as light elements, encapsulated inside dense materials. However, neutron radiography is not a widely used technique due to the nature of its very niche use cases. For this reason, very few ASNT certified neutron radiographers exist today, with the numbers continually dwindling. The certified test questions have not kept up with recent advancements in neutron imaging and the certification has been all but cancelled. It is important that this certification by an objective 3rd party remain alive and well for future uses of neutron imaging in the fields of aerospace, medical, automotive, and defense and homeland security, to name a few. A new task group has been formed within ASNT to revive the certification program for neutron imaging. This task group is comprised of several subject matter experts from industry, national research institutions, and academia, to create new technical content and exam questions for certification of the ASNT neutron radiography inspection method. Specific aims of the task group will be reported, as will the most recent progress in the certification program. A projection of what the revised certification program will look like will be presented, as will a timeline for completion, and criteria for acceptable application to the certification program.

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Model-Assisted Validation of Sensor Networks – Fellowship Award

Presenting author(s): Ms Jin Yan

Co-Authors:

Room: Virtual Room | 2:30 PM Tuesday, November 10, 2020

Recent sensing advances empower the deployment of dense sensor networks (DSNs) that can be used in automating the condition assessment process of large-scale structural and mechanical systems. To fully enable DSN technologies, it is critical to develop and implement co-design techniques that allow for the evaluation of their performance to attain the condition assessment targets. In this paper, we propose a methodology to validate the design of DSNs. The methodology consists of constructing a physical surrogate of the DSN-equipped component based on the sensor configuration, updating the physical surrogate using sliding mode theory based on generated or collected sensor data, and quantifying the performance of the DSN based on model assisted probability of detection theory. The proposed methodology is numerically verified and validated on a cantilever beam subjected to damage at its root and equipped with a network of soft elastomeric capacitors measuring strain. Various uncertainties are considered in the simulated system. The verification consists of confirming the capability of the adaptive process for the surrogate model at reaching an accurate representation of the full system. The validation consists of ranking the performance of various DSN configuration and benchmarking results against those obtained from the full finite element model. Results show that the proposed methodology can be used to evaluate the performance of DSN configurations, but that the damage thresholds used in determining damage need calibration for successful field applications.

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Feature Extraction and Porosity Assessment on Thick Stainless Steel 316 Samples with Embedded Slots

Presenting author(s): Mr John Miers

Co-Authors: Mr David G Moore

Room: Virtual Room | 2:30 PM Tuesday, November 10, 2020

X-Ray Computed Tomography (XCT) is a common technique for evaluating Additively Manufactured (AM) components. The present work uses XCT to measure an array of stainless steel 316 uniaxial tensile specimens with embedded slots throughout the grip length. The samples are scanned simultaneously, stacked front to back with uniform spacing, in a 450 kV cabinet system. The data is reconstructed and evaluated in Volume Graphics VGStudioMAX^TM 3.3. Enhanced segmentation methods are used to extract the gage region of each component beyond the influence of noise. Within each gage region the measurement of geometric features and the assessment of porosity is performed. The lower internal signal-to-noise ratio and presence of common artifacts in thick components elicits greater uncertainty in their porosity assessment. Comparisons are drawn between porosity analyses using one of the industry standard solutions. Porosity distribution around the top and bottom, relative to the build direction, of each slot was found to be greater than that of the bulk of the material. Angular deviation and flatness of the gage and slot surfaces are reported. The limitations of XCT in relation to reliable feature extraction, signal-to-noise ratio, part thickness, and ideal voxel size are discussed. Finally, the implications of these results are summarized and recommendations about the information that needs to be given to designers and producers of AM components are made

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Nondestructive Evaluation for Bridge Decks and Prestressed Concrete Structures

Presenting author(s): Dr Shane D Boone

Co-Authors:

Room: N/A | 3:00 PM Tuesday, November 10, 2020

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Surface Determination of Additively Manufactured SS316-L Lattices Using Supervised Machine Learning

Presenting author(s): Mr Collin Epstein

Co-Authors: Mr Andrew P Lentfer, Ms Caroline Massey, Mr David G Moore

Room: Virtual Room | 3:00 PM Tuesday, November 10, 2020

Metal additive manufacturing has enabled the fabrication of intricate component geometries that present challenges to non-destructive inspection using computed tomography. Periodic patterns of high-attenuation material create significant beam-hardening artifacts in computed tomography reconstructions. Such artifacts make sample surface determination for component analysis prohibitively difficult with traditional search-detect-evaluate techniques. This presentation will discuss the limitations of computed tomography, creation of artifacts during variable inspection scan times and experiments on applying supervised machine learning (ML). The results will be summarized, and potential surface determination techniques will be presented.

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Process for Nondestructive Testing of Prestressed Concrete Using Electronic Distance Measurements to Measure 3-D Coordinates of Cardinal Points While Tensioning/Detensioning Tendons

Presenting author(s): Mr David H Parker

Co-Authors:

Room: Virtual Room | 3:30 PM Tuesday, November 10, 2020

This is a companion paper to Opportunities for the use of electronic distance measurement instruments in nondestructive testing and structural health monitoring and implications for ASNT, which was presented at the 2018 ASNT Research Symposium. The earlier paper covered the background and capabilities of electronic distance measurement instruments, and in general how they could be used for nondestructive testing applications, which will not be repeated. This paper covers specific applications limited to prestressed concrete structures, such as slabs, columns, girders, bridges, towers, silos, cooling towers, wind power generation towers, liquefied gas storage tanks, nuclear power containment buildings, and the like—in particular during the process of tensioning/detensioning tendons. A number of failures have occurred coincident with the tensioning/detensioning process. Most recently, in the well documented OSHA investigation of the 2018 collapse of the Florida International University pedestrian bridge, cracks occurred while detensioning tendons in a diagonal member, and the collapse occurred while re-tensioning the tendons. Other notable documented failures include; the Las Lomas Bridge, the Kapiolani Interchange On-Ramp, and Turkey Point Unit 3 and Crystal River Unit 3 Nuclear Power Plants. It will be argued that high accuracy 3-D coordinate measurements of cardinal points on a structure should be included in future tensioning/detensioning plans in order to provide real-time feedback as to the performance of the structure. An example experimental architecture and 3-D uncertainty analysis, using manufacturers instrument specifications and commercially available software is included for nondestructive testing—using the Florida International University pedestrian bridge as a representative structure.

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Characterization of Additively Manufactured Samples with Mechanical Testing and Nondestructive Inspection Techniques – A Path Forward for Qualification

Presenting author(s): Mr David G Moore

Co-Authors: Ms Ciji L Nelson

Room: Virtual Room | 3:30 PM Tuesday, November 10, 2020

Additively manufactured (AM) components contain discontinuities, indications and defects that can change the component’s mechanical performance during qualification or while the part is in-service. The inspection uncertainty and misidentification of discontinuities created during the AM build is not a desirable manufacturing process for aerospace applications. Current research at Sandia National Laboratories is addressing these concerns by focusing on mechanical characteristics and nondestructive inspection methods to assess uniaxial tensile specimens which in turn, will optimize the set-up parameters. This presentation focuses on a direct metal laser sintering (DMLS) powder bed fusion machine which is being prepared for production activity. A background on Sandia National Laboratories’ research efforts and how nondestructive evaluation assists design teams will be described. Several case studies will be summarized. Computed tomography, eddy current and ultrasonic test methods will inspect the same sample and the advantages and disadvantages of each inspection method will be presented. A combination of material strength testing, microstructural analysis and nondestructive inspection techniques will also be described along with a roadmap for determining inspection limits for the qualification of AM materials.

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The Future of NDT Certification

Presenting author(s): Mr Michael R Collingwood

Co-Authors:

Room: Virtual Room | 4:30 PM Tuesday, November 10, 2020

Current NDT certification schemes are based upon concepts originating in the 1960’s. This was a far simpler time when the methods used X-ray, Ultrasonic, Magnetic Particle and Liquid Penetrant. Todays NDT technology includes a maelstrom of technologies for more varied and complex then ever envisioned by the writers of SNT-TC-1A, MIL-410 or any of the current documents including NAS-410 and EN-4179! This presentation will highlight some of the todays technological divergence and complexity, discuss the continued relevance of the current industry standards for certification and possible alternatives.

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Early-stage detection of Chloride Stress Corrosion Cracking (CSCC) in stainless steel components using Eddy Current Array

Presenting author(s): Ms Anne Marie Allard

Co-Authors: Mr Michael Sirois, Mr Olivier Bellavance

Room: Virtual Room | 4:30 PM Tuesday, November 10, 2020

Corrosion resistance of Stainless Steel (SS) is limited and susceptible to external crevices and pitting in some environments or contexts of use. Pitting and crevices act as initiating points for chloride induced stress corrosion cracking (CSCC). Components affected by this are used for a wide variety of applications and the criticality of the assets also varies, but the damage and related risks cannot be ignored. Presence of seawater is a well-known cause for CSCC, but this issue is not limited to assets near seacoasts. Chemical processing plants and petrochemical plants are also threatened by this damage mechanism. One can easily imagine that failure of a vessel or pipe could put the safety of workers at risk or lead to the release of hazardous chemicals in the environment. Such event would impact the integrity of the plant and incur loss of performance and costs for repair. In addition, these disastrous events could potentially have a huge impact on the environment and on the population’s health. Another example is the dry storage canisters for spent nuclear fuel, also vulnerable to CSCC: mitigating the impact of a nuclear compound leak is almost impossible and impacts spread over a very long period of time. Frequent monitoring is an optimal and cost-effective way to prevent failure due to CSCC. Current inspection methods such as penetrant testing (PT) and visual inspection (VI) require extensive cleaning and surface preparation. Slow speed and use of chemicals have been reported as major downsides by asset owners. In addition, human factor is also an important element impacting the probability of detection (PoD) and inspection reliability. Record-keeping and auditing are also quite limited as no digitalization is possible (with spatial referencing). Eddy Current Array (ECA) has proven to be a highly effective solution for the detection of CSCC in SS components. Combining high resolution and sensitivity, it has the capability to detect CSCC at its very early stage. The wide coverage contributes to carrying out reliable inspections at high speed, reducing shut down time and overall costs. Portable electronics, advanced analysis software and adapted ECA probes make the deployment and use of ECA easier and faster than other methods. Moreover, data visualization coupled with archiving capabilities also enable monitoring the evolution of the indications over time. This paper discusses the benefits of ECA in general and introduces a complete field proven ECA solution for detection of CSCC in SS components. Key applications and results from field inspections are also discussed.

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Self-Employment

Presenting author(s): Mr Michael V McGloin

Co-Authors:

Room: Virtual Room | 5:00 PM Tuesday, November 10, 2020

Have you ever thought of going into business for yourself so that you can look forward to the freedom and independence of self-employment? When one gets this thought, they generally put together a list of pros and cons. What they do not add to the list is all of the unknowns and unexpected items that come up. This talk will go over some of those unknown and unexpected items which should help people to better prepare for entrepreneurship.

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Evaluation of Variability in the Magnetic Particle Inspection Process in Steel Castings

Presenting author(s): Ms Sharon Lau

Co-Authors: Dr David J Eisenmann, Mr Frank Peters

Room: Virtual Room | 5:00 PM Tuesday, November 10, 2020

The quality of an inspection relies on the equipment, process, and human operator. The objective of this paper is to study the measurement variability due to surface roughness, geometry, and human operator in magnetic particle inspection (MPI). Steel castings have rougher surfaces than machined parts which makes this an important factor to investigate because of unevenness on the surface cause the particles to collect and may result in false positives or prevent the human operator from finding true defects. To study the effect of surface roughness on the effectiveness of wet MPI, two metrics were developed. The quantity of particles, measured as the green pixel value, can objectively determine the amount of particles accumulated on the surface, and noise area percentage is a metric to quantify how well indications show up. An advantage of castings is their complex geometries; however, this geometry creates a variance in the magnetic field strength on the part. Hence, if a process is not properly set up to account for the effect of geometry on the magnetic field strength, indications may not be identified in regions where the magnetic field strength is low. Parts with different geometries were tested and the magnetic field strength was measured using a gauss meter. Lastly, a gauge repeatability and reproducibility (R&R) study was performed in two foundries to investigate the human error in wet MPI. The R&R results were reported as the ‘percent of matches’ for resultant inspections of the same casting. Overall, rougher surfaces were found to negatively influence the reliability of wet MPI. As for the effect of geometry, magnetic field strength was found to decrease as the radius of an area increases. The gauge R&R results show the inspection process is highly subjective with an average match between subsequent inspections by was 25% as well as 25% when compared across inspectors.

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Managing Your NDT Career in the New Norm

Presenting author(s): Ms Jill Lutz

Co-Authors:

Room: Virtual Room | 5:30 PM Tuesday, November 10, 2020

Even before COVID-19 changed the employment landscape for practically everyone, finding a job within
the skilled trades has been evolving for quite some time. With the growing use of applicant tracking
systems (ATS) in many mid to large-sized companies, applying for and landing the next best job can be
challenging if prospective candidates aren’t using technology to their advantage. How do nondestructive
technicians and other industrial inspectors make their capabilities stand out, so they can plan—and
position themselves for—their next best career move?

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Practical assessment of current fatigue and stress state of steel structures configuration by NDT method measuring steel magnetic property – coercivity

Presenting author(s): Mr Roman Solomakha

Co-Authors: Dr Gennadiy Bezliudko, Ms Svitlana Savluk

Room: Virtual Room | 5:30 PM Tuesday, November 10, 2020

Capability of steel to withstand mechanical loads decreases with aging. Beginning from the start of essential fatigue changes - microdamage accumulation – such decrease is more and more evident. There is the most intensive accumulation of fatigue deterioration in stress concentration zones. As higher is fatigue accumulation as less is a maximum stress value which the steel could withstand without rupture. Number of loading cycles which the steel could withstand without rupture decreases as well. At the last stage of fatigue accumulation, the steel is not capable to withstand allowable stress value and failure starts. All the stages of fatigue degradation under operation load are identifiable and assessed by the method measuring steel magnetic property – coercivity. It should be mentioned that fatigue flaw can, but not necessary, appear only at the very last and shortest stage of service life. With intensive operation mode period between scheduled inspections can be shorter than last service life stage. In such cases fatigue flaws would not be detected and correspondently the failure would not be prevented. Moreover, detection of fatigue flaws at steel structure in operation is much more time- and labour-consuming than detection of stress concentration zones, which are at the same time zones of accelerated fatigue accumulation. Numerous cases of failure without fatigue cracks are also known for the metal in state of prefracture. There are results of destructive bench tests of structural steel samples with simultaneous coercimetrical testing until rupture stated in the paper. Results of coercimetrical inspection of steel structures such as blast furnace shell, ship hull, cowper dome, milling roll, pipeline and others are shown as well. Joint coercimetrical assessment of stress and fatigue state enables to detect maximal allowable stress value for metal in the particular state as it is in operating steel structure. This allows to make residual service life forecast on the base of actual state of the weakest part of tested object. Also, such assessment makes possible prevention of fatigue failure of metal which is still flawless but is already in state of prefracture.

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Achieving High Speed and High Detectability in Eddy Current Testing using Ultra High Multi Channels and Digitalization in Stationary and Rotary sensor systems

Presenting author(s): Mr Ulrich Brandle

Co-Authors: Mr Hari Muthuswami

Room: Virtual Room | 10:00 AM Wednesday, November 11, 2020

This presentation discusses a new approach to the almost contradictory objective of high speed and high detectability that are being set in eddy current testing of long products such as tubes, bars and wires with a combination of precision high speed mechanics and modern electronics. The modular design approach makes it suitable to be expanded to other techniques as well in the future. Easily configurable with Ultra Large Multi-channels for Stationary or Rotary sensors, makes the concept extremely cost effective. The presentation also discusses how the concept reduces downtime and running costs enabling investors to obtain high uptimes and short ROIs. The new solution keeps in mind the necessity and the demands of today’s industry for Data Acquisition, and Data Transfer to remote users making it a step towards NDE4.0. The presentation also discusses a hitherto unachieved function of Clearance Compensation in Stationary Sensors accomplished using a multi-channel stationary sensor with additional windings to monitor variation in clearance and automatic adjustment of Amplifier gain.

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Inspection of Coarse Grain Welds using TFM Techniques

Presenting author(s): Dr Olivier Roy

Co-Authors:

Room: Virtual Room | 10:00 AM Wednesday, November 11, 2020

Many advanced PAUT instruments now offer FMC / TFM imaging techniques. TFM imaging is increasingly recognized in the field of non-destructive testing for its qualities: realistic images over an extended region with optimized resolution facilitating the analysis and interpretation of results. These techniques also allow for simplified setup of control configurations for faster and safer inspection work. Standards development is progressing in the ASME and IIW working groups to qualify these techniques, and the number of successful applications in industrial fields is increasing. However, TFM imaging must respect the physics of ultrasound to produce relevant images. Components with a complex material or even a large thickness requires the use of transducers with a large active surface to increase the energy transmitted in the material and increase the focusing capacity to optimize the spatial resolution for the detection of small defects. A large aperture also improves the signal-to-noise ratio in the presence of structural noise. This article will present several weld inspection applications in which TFM imaging can be advantageously applied compared to PAUT techniques, using the appropriate transducer and TFM option. The large aperture is reinforced with TRL transducers that can improve defect detection in complex materials at a chosen depth. The combination of these PA dual transducers with the TFM method produces high quality imaging with all the additional benefits. In the case of attenuating material, or for very thick parts, TFM imaging can be enhanced by using a different excitation mode, PWI, transmitting more energy to increase sensitivity and detection capabilities. Applications and results are presented to illustrate the advantages of TFM techniques for weld inspections on CRA and coarse grain structure components. These results were achieved using a field portable device applying standard PAUT techniques and different options of TFM techniques applied on a PA transducer with up to 128 elements.

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Leadership in NDT

Presenting author(s): Ms Caroline Bull

Co-Authors:

Room: Virtual Room | 10:00 AM Wednesday, November 11, 2020

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Digitalization to Lay a Foundation for NDE 4.0

Presenting author(s): Mrs Nasrin Azari

Co-Authors:

Room: Virtual Room | 10:30 AM Wednesday, November 11, 2020

NDT companies are recognizing the importance of digitizing data and automating testing and inspection processes in order to adapt more quickly to new business requirements and operate more efficiently and effectively. Digitizing all data collection and creating digitized processes enable an organized, consistent, approach to data management that also helps to lay a critical foundation for incorporating NDE 4.0 technologies. In this session, Ms. Azari identifies the long-term benefits of digital transformation for NDT companies, and how to create a roadmap that will take your company from where it is today to where you want to be with respect to NDE 4.0.

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Improvements in the Ultrasonic Inspection of Cast Austenitic Stainless Steel (CASS) using Advanced Total Focusing Methods

Presenting author(s): Mr Alan Caulder

Co-Authors:

Room: Virtual Room | 10:30 AM Wednesday, November 11, 2020

The ultrasonic inspection of Cast Austenitic Stainless Steel (CASS) has historically been a very challenging endeavor. The casting process creates a coarse and dispersive grain structure that results in material properties that attenuate and scatter the propagated sound waves. These characteristics have required inspections to be performed with low frequency and low resolution techniques, making accurate crack detection and sizing extremely difficult. Recent advancements in advanced ultrasonic images, such as TFM (Total Focusing Method), and more specifically derivative algorithms PWI (Plane Wave Imaging) and VSA (Virtual Source Aperture), may offer a significant improvement over current methods by allowing much higher frequencies to be used, yielding better sizing accuracy and overall detection. The superior focusing abilities of these methods over conventional single or dual element ultrasound and PAUT (Phased Array Ultrasound) also offer improvements in signal-to-noise ratio when using historically accepted frequencies. We will share PWI and VSA inspection results from several flawed CASS mockups using a frequency spectrum that was historically thought unusable for the material category. Through a thorough analysis of these results, we are also able to provide insight to the future development and improvement of these approaches by identifying additional technical improvements that may be implemented to further advance the inspection of CASS.

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Panel Discussion

Presenting author(s):

Co-Authors: Ms Caroline Bull

Room: Virtual Room | 10:30 AM Wednesday, November 11, 2020

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Evaluation of curvature effects on the performance of an integrated robotic gripper equipped with electromagnetic acoustic transducers

Presenting author(s): Mr Hamidreza Nemati Noghlebari

Co-Authors:

Room: Virtual Room | 11:30 AM Wednesday, November 11, 2020

Electromagnetic Acoustic Transducers (EMATs) are non-contact, ultrasonic transducers widely used in nondestructive testing (NDT). Shear Horizontal (SH) bulk, and SH guided wave inspection of engineering structures have been proven to be effective in several industrial applications. However, there are still many unknown aspects of these waves’ behavior. One of these aspects is the curvature effect which can substantially change the physical properties of the Guided waves. This research provides an experimental study to investigate the effects of curvature on Guided waves excitation using Lorentz force-based EMATs. The understanding of curvature effect will allow the research team to optimally design an automatic inspection system (nondestructive inspection robot), integrated with EMAT. The robot has two grippers equipped with EMATs and will be used for inspection of tubular components. To assess the impact of curvature on Guided waves, tubes with different diameters are considered. The tests have been performed with the pitch-catch configuration (different transmitter and receiver). Some important indexes including amplitude, energy and time of flight correlated to tubes with different curvatures are obtained. This study aims to pioneer a new technique for automatic inspection of tubular components, which can also be applied to coated steel pipes and cylinders.

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Solving for HTHA Single Sided Access Inspection with Dual Linear Probe

Presenting author(s): Mr Mohamed Aly Souissi »

Co-Authors: Ms Emilie Peloquin

Room: Virtual Room | 11:30 AM Wednesday, November 11, 2020

HTHA (High Temperature Hydrogen Attack) damage mechnasism has been heavily under the microscope in the past years. Many new inpsection techniques, as well as former more familiar techniques are now being used in conjonction to ensure detectability for this intergranular damage. The present paper offers a new approach to HTHA inspection in times where access to the component is physically limited to one side of the weld only. This challenging scenario is common in the field as components are often welded to a flange or a fitting which prevents from putting a Ultrasonic probe on each side of the weld. This new inspection strategy allowed for more energy penetrating the component as well as a reduced surface noise and was also found to be overall less noisy then other methods like TFM and PAUT conventional

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Leading Through Change - Part 1

Presenting author(s): Ms Karen Smith

Co-Authors:

Room: Virtual Room | 11:30 AM Wednesday, November 11, 2020

Few change initiatives succeed in today’s complex global environments. For the best chance of success, leaders need to be able to gauge and respond to others’ resistance and inspire their team members to take ownership of change.  I have been through so much change in our industry and organization and will discuss success drivers that I have learned along the way.

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How to Set your Industry 4.0 Digital Journey into Motion

Presenting author(s): Mr Greg Bauer

Co-Authors: Mr Kim Fraga

Room: Virtual Room | 12:00 PM Wednesday, November 11, 2020

NDT organizations worldwide are realizing the significance of Industry 4.0 and the value of investing in digital platforms, but many companies are finding it difficult to know where and how to start. Join this session to learn how to embark on your digital journey. We will discuss how to kickstart this process, which involves the critical first step of assessing your current work processes to determine major paint points. Maybe it’s the collection and management of NDT data? Maybe it’s report generation or resource management? Taking a close look at these pain points enables you to gather valuable insights and determine where digital tools may be most helpful. Ultimately, there are infinite possibilities of what can be done with digital tools, but targeting solutions too broadly can result in paying for more than is necessary and struggling to adopt. We will share client case studies to provide context on how this process benefits your organization’s digital adoption. In closing, we will discuss how to prioritize and find solutions that will improve your workflows, saving your company time and money.

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Analyzing Behavior of Temperature Varying Material Systems Through Acoustic Measurements - Fellowship Award Winner

Presenting author(s): Mr Tyler Watson

Co-Authors: Dr David Jack, Mr David G Moore

Room: Virtual Room | 12:00 PM Wednesday, November 11, 2020

The use of acoustic measurements to identify the internal thermal and phase state of an amorphous material is of interest within multiple industries, specifically in the petro-chemical industry for materials transport and the polymer processing industry for in-situ thermal measurements. The present study focuses on the drastically different behavior between two material systems, an ecosoya wax and a machinist wax. These two systems both experience a range of temperatures over which the material softens prior to melting, but based on the external boundary conditions and cooling rate they will experience drastically different internal structures. Specifically, the ecosoya wax tends to form a homogeneous medium during cooling in an unconfined container, whereas the machinist wax will form a porous internal structure if cooled at the same rate. In the present study we study the change in the acoustic profile between these two systems subjected to a quasi-isothermal state experienced during a slow heating and subsequent cooling period lasting several days. The acoustic behavior is studied via through transmission ultrasound over acoustic paths that range from 4” to 10”. The experimental setup includes placing the molten wax within an acrylic box containing multiple thermocouples for monitoring. The wax was placed inside a furnace and slowly stepped in either increasing or decreasing temperature with step sizes 5°C or less. At every desired step, two transducers are attached to the container and the through transmission acoustic profile is captured along both axes. Results show that for the amorphous ecosoya wax the speed of sound is a one-to-one relationship with the internal temperature state. Conversely, the speed of sound is not a good metric for quantifying the internal temperature state for the machinist’s wax due to the presence of many internal voids. The analysis of the machinist’s wax waveform indicates that select aspects of the frequency spectrum and corresponding energy of the waveform is a better predictor of the internal temperature state. To add to the challenge of the machinist’s wax analysis, there is a clear hysteresis in the behavior as a function of cooling where the acoustic profile during heating was different than that of cooling at the same quasi-isothermal state.

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Leading Through Change Part 2

Presenting author(s): Ms Karen Smith

Co-Authors:

Room: Virtual Room | 12:00 PM Wednesday, November 11, 2020

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NDE 4.0 Dialogue with a Panel

Presenting author(s):

Co-Authors: Dr Roman Gr Maev, Ms Marybeth N Miceli, Dr Ripudaman Singh, Dr Johannes L Vrana

Room: Virtual Room | 12:30 PM Wednesday, November 11, 2020

This will be an open forum to engage in a conversation with a panel of experts on NDE 4.0 - Johannes Vrana, Ripi Singh, Roman Maev

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Experimental evaluation of friction effects on Lamb waves generation

Presenting author(s): Mr Sina Zamen

Co-Authors:

Room: Virtual Room | 12:30 PM Wednesday, November 11, 2020

As one of the most common physical processes, friction has considerable practical importance while it is not very well understood yet. Generation of ultrasonic waves up to 10 GHz has been reported in dry sliding friction, where there is no lubricant between two solids that are sliding with respect to each other. In this research, the role of friction in generation of Lamb waves using piezoelectric transducers is experimentally studied. Piezoelectric materials used in transducers can usually have both in plane and out of plane movements. Constraining out of plane movement of piezoelectric transducer by applying a normal load, one can change the transmission energy to generate Lamb waves in plates. In this study, the generation of Lamb waves and their frequency domain response is experimentally studied. The piezoelectric transducer is attached to a micro-fabricated friction pad which has direction-dependent friction coefficients due to its topological features. Hence, by measuring friction coefficient of pad with the corresponding generated Lamb waves in different directions and under different normal loads, the effect of friction in generation of Lamb waves is studied.

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Leading Through Change Part 3

Presenting author(s): Ms Karen Smith

Co-Authors:

Room: Virtual Room | 12:30 PM Wednesday, November 11, 2020

Few change initiatives succeed in today’s complex global environments. For the best chance of success, leaders need to be able to gauge and respond to others’ resistance and inspire their team members to take ownership of change.  I have been through so much change in our industry and organization and will discuss success drivers that I have learned along the way.

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Designing Radiation Shielding for NDT

Presenting author(s): Mr Paul Rochus

Co-Authors:

Room: Virtual Room | 2:30 PM Wednesday, November 11, 2020

Radiation protection is a concern across a wide range of industries from healthcare and medical imaging to nuclear energy and nuclear medicine. In the field of non-destructive testing (NDT), radiation safety is especially important to maximize the safety of workers. Considering all the factors and the different types of materials to choose from for shielding radiation, understanding the capabilities of materials will help to find most effective solutions to specific shielding needs. ALARA (“as low as reasonably achievable”) is a principle that strives to minimize the exposure of ionizing radiation to people and the environment while considering economics, technology, and social factors. When using radiography to inspect welds, materials, or manufactured parts, high-energy sources like cobalt 60 (Co-60) or iridium 192 (Ir-192) are often used as well as lower-energy X-rays. ALARA needs to be considered over the lifetime of the source, not just when performing radiography analysis. This includes potential maintenance, transportation, and decommissioning at the end of the lifetime of the source. The three principles of ALARA to reduce dose to workers are time, distance, and shielding. Time and distance are two factors that can be greatly limited by the facility where the testing is taking place, setup procedures, and monitoring procedures during the test. Therefore, shielding becomes the most important factor to control and modify in order to maximize safety and limit radiation exposure.

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TBA - Pipeline

Presenting author(s):

Co-Authors:

Room: Virtual Room | 2:30 PM Wednesday, November 11, 2020

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Interviewing Skills for the Interviewee

Presenting author(s): Mrs Karen L Bruer

Co-Authors:

Room: Virtual Room | 2:30 PM Wednesday, November 11, 2020

In order to have a successful job interview, there are basic and specific skills each candidate should know prior to arriving at the meeting.  This talk will focus on the do’s and don’ts each candidate should know and learn to make the best impression on the hiring manager, and how to highlight specific skills.  Normally, there are no second chances to overcome a bad interview, so set yourself to be your best.

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Optimization of the Radiating Subsystem in Active Microwave Thermography

Presenting author(s): Mr Ali Mirala

Co-Authors:

Room: Virtual Room | 3:00 PM Wednesday, November 11, 2020

Active microwave thermography (AMT) refers to a nondestructive testing technique that uses microwave radiation as the thermal source and a thermal camera to measure the resulting surface temperature distribution. For structures that absorb microwave radiation, a microwave-based thermal excitation may be superior to other thermographic excitations (e.g., traditional flash lamp). To this end, this technique has recently shown promise for inspection of different categories of structures, e.g., conductive/metallic, composite, cement-based, radar absorbing, etc. However, while the potential for AMT to serve as a nondestructive testing technique has been well-established, little has been done to optimize the microwave radiating subsystem (which consists of a single or an array of antennas) in AMT systems. Optimization of this subsystem will result in a more efficient use of microwave energy by maximizing the induced thermal contrast with reduced heating times, and better induction of thermal energy as the excitation may be tailored to specific materials/structures. Also, an optimized radiating subsystem may also be capable of increasing the uniformity of the microwave hence the induced thermal excitation. This has important practical ramifications related to reliable defect detection (as a non-uniform excitation brings with it the risk of a masked defect). Physically speaking, placement of the thermal camera (for proper viewing) can also be integrated into the optimized design. To this end, this research studies the effect of antenna type such as horn, patch, array, etc. on the performance of the microwave radiating subsystem (and AMT inspection quality overall) with several representative simulation and measurement results presented.

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Improving Phased Array Beam Divergence in Small Diameter, Pipe Weld Insepction

Presenting author(s): Mr Curtis James Dickinson

Co-Authors:

Room: Virtual Room | 3:00 PM Wednesday, November 11, 2020

Ultrasonic Phased Array inspection of small diameter pipe welds present many different challenges. One such challenge is the divergence of the phased array beam that occurs upon entering the pipe surface and from reflecting off the ID surface. This divergence caused by the size of the transducer elements can cause a loss in sensitivity as well as errors in measuring the length of indications detected. Through the use of a novel wedge design, this presentations aims to show the concepts and means by which the quality and consistency of your small diameter weld inspections can be improved in this regard.

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Salary Negotiation Tips

Presenting author(s): Ms Shana Telesz

Co-Authors:

Room: Virtual Room | 3:00 PM Wednesday, November 11, 2020

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Model-Based Studies of Eddy Current Sensors for the Characterization of Corrosion Under Coatings

Presenting author(s): Mr Daniel Bartles

Co-Authors: Mr Eric Tarkelson, Dr Mahmoodul Haq, Dr Lalita Udpa, Tom Sanders

Room: Virtual Room | 3:30 PM Wednesday, November 11, 2020

Steel and aluminum infrastructures can corrode when exposed to harsh environmental conditions, such as extreme moisture or temperature, and consequently these structures are coated with protective layers in an effort to reduce corrosion damage. However, since the corrosion is hidden by paint or coatings with certain electrical and magnetic properties, the damage can be detected visually only after the paint blisters, which occurs after the corrosion damage has become a problem. Hence, there is a need for developing methods for early detection and quantification of corrosion under coatings. This paper investigates the development of an eddy current sensor array system for early detection and quantification of corrosion under coating in steel and aluminum samples. The feasibility and effectiveness of the approach is investigated using a combination of model-based and experimental data. A validated numerical model is used to predict the probe response to small surface defects concealed beneath a layer of paint or other protective coating. In particular, we consider corrosion damage with arbitrary electromagnetic material properties – e.g. electric conductivity, magnetic permeability. Stochastic techniques are implemented in the corrosion region, allowing a more realistic representation of the corrosion profile due to a random distribution of corrosion byproducts. The simulation results are used as training data for a neural network designed to characterize the severity and depth profile of the corrosion, particularly with regard to different properties of coating material.

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Portable X-Ray Fluorescence for In-Field Testing of Mercury (Hg) Contamination in Petrochemical Process Piping

Presenting author(s): Dr Michael Hull

Co-Authors: Mr Joshua Litofsky

Room: Virtual Room | 3:30 PM Wednesday, November 11, 2020

Quickly and accurately detecting mercury contamination in process piping is a fundamental need for the petrochemical industry. Virtually all petroleum contains some amount of mercury compounds. The mercury present in the crude oil can amalgamate with the steel in the process piping, storage tanks, and marine vessels. This mercury accumulation poses additional challenges during decommissioning, so it is essential that the mercury contamination is identified, quantified, and properly disposed of. Portable X-ray fluorescence (XRF) provides a fast and accurate means of quantifying mercury contamination in piping, with microgram per square centimeter (µg/cm2) detection. In a matter of seconds, portable XRF can quantify the degree of mercury intercalation into the surface of the steel piping. Using portable XRF on-site prior to demolition enables asset owners to make informed decisions during decommissioning and helps prevent contaminated material from entering the recycling stream. In this paper, we present quantitative results that substantiate the performance of portable XRF for detecting mercury contamination in piping. Recommended testing protocols are discussed as well common concerns about interferences in testing methods. Additional advances in instrument connectivity allow real-time result sharing, even between remote locations.

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Panel: How to Handle Curve Balls

Presenting author(s): Ms Molly Dulle

Co-Authors:

Room: Virtual Room | 3:30 PM Wednesday, November 11, 2020

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Exposure Guidance for Digital Detector Array Radiography

Presenting author(s): Mr Brian S White

Co-Authors:

Room: Virtual Room | 4:30 PM Wednesday, November 11, 2020

Exposure factors (R factors) have been utilized for decades to provide guidance in gamma radiography applications, and have been published for Carestream digital detector array (DDA) radiography systems. By knowing the target pixel intensity through the base metal to achieve sensitivity, R factor tables can be utilized to set the required DDA integration time. This paper provides a recommended pixel intensity range to achieve required radiographic contrast sensitivity.

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Rapid Surface Inspection of Storage Tank Welds Using Next Generation ACFMT Array Probes

Presenting author(s): Charles Tremblay

Co-Authors: Dr Michael C Smith

Room: Virtual Room | 4:30 PM Wednesday, November 11, 2020

The pressures from unprecedented demand for oil storage during the Spring/Summer of 2020 highlights that assessing the integrity of petrochemical storage tanks is vital in ensuring the economic operation of these assets and for the avoidance of environmental contamination. While corrosion proves to be the dominant damage mechanism affecting tank floors, the formation of cracking in the tank plate welds is also one which needs to be detected and assessed. Conventional surface inspection techniques, such as MT, require clean metal to perform optimally, which entails extensive cleaning - adding cost, time and generating waste. Inspections are relatively slow, operator subjective and do not provide an auditable record. In addition, they only give assessment of crack surface length and not crack depth, which is the more critical dimension in determining the severity of a defect for structural integrity. In the past, Alternating Current Field Measurement Testing (ACFMT) has proved to be an effective alternative method for detecting and sizing cracks without the need for extensive pre-cleaning (it can even operate through paint or coatings) and for giving a determination of crack depth usually without the need for on-site calibration. However, the probe sensor area has typically been small which requires several passes of the probe on a weld cap. Multi-sensor arrays have existed, but the scan speed has been low due to restrictions with the instrumentation. A new generation of ACFMT instrumentation, featuring substantially faster and higher resolution data acquisition, has enabled the development of larger sensor arrays that can be deployed at a speed much more conducive to effective and productive inspections. One such array is considered here which features 16 compliant fingers covering a width of 90mm (3.5”). This can inspect wide butt welds or lap welds on plate up to 13mm (0.5”) thick for defects in both longitudinal and transverse orientations in one pass of the probe. Lab based performance tests are supplemented by in-service trials which demonstrate that the new probe and instrumentation provide a rapid and effective inspection methodology for storage tank welds.

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POD Study Challenges for Aerospace ET NDT & SHM

Presenting author(s): Dr Neil J Goldfine

Co-Authors:

Room: Virtual Room | 5:00 PM Wednesday, November 11, 2020

This paper is focused on qualification challenges for both nondestructive testing (NDT) and structural health monitoring (SHM); where the SHM focus is limited to permanently installed sensors to replace traditional NDT in challenging access locations, but with only the sensors and cables flying on the aircraft, rotorcraft, unmanned vehicle, or spacecraft. Only eddy current sensors are addressed; however, many of the lessons learned apply to other NDT methods. The purpose of this paper is to establish the state of the art for MWM-Array eddy current sensor technology; and more broadly, for other foil type arrays, instrumentation and inspection methods that provide fully parallel data acquisition from all channels, simultaneous impedance measurement (at multiple frequencies when needed), and use model based methods to estimate multiple properties (such as crack response and liftoff). The focus is on surface and buried crack detection, but many of the lessons learned also apply to corrosion studies. This presentation also includes a discussion of real crack sample fabrication for NDT performance studies, as well as fatigue testing of coupons and subcomponents for generation of POD curves for installed sensor qualification. This includes both results of historical studies over more than a decade along with ongoing and recently completed studies.

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Total Inspection Efficiency – Evolution of Tank Floor Scanning

Presenting author(s): Mr Stuart Paul Kenny

Co-Authors: Mr Matthew Boat

Room: Virtual Room | 5:00 PM Wednesday, November 11, 2020

Above Ground Storage tanks are subject to obligatory and periodic inspection routines. Due to the harsh operating environments and the catastrophic impact of failure, storage facilities are governed by regulatory practices to ensure the assets are fit for service. There are numerous potential damage mechanisms associated to the in-service operation of tank storage and each risk of failure requires careful management and routine inspection. Underfloor corrosion is specifically related to the soil interface underneath the tank floor. Regarded as one of the most significant threats in tank storage, floor corrosion often is identified as a risk during integrity management programs and inspection of this potential defect will regularly be included within the written scheme of examination/inspection. Due to the large service area of a tank floor, the typical inservice condition of the scanning service and the general working conditions inside a storage tank, the inspection method identified to detect underfloor corrosion, must be fast, robust, reliable and provide a high value of confidence for minimum detectability. Magnetic Flux Leakage systems have been historically deployed for this part of the inspection process and the technology has a proven track record for being able to provide consistent results within these harsh and uncomfortable environments. However, the historical practices have been challenged for inefficiency and asset owners are insisting for improved productivity, without sacrificing accuracy and traceability. The latest generation of MFL technology has been developed to significantly improve inspection efficiencies and has identified specific areas within the work flow and scanning parameters that can provide an asset owner with a final report in as minimal time as possible. This results in direct cost savings for reduction in labor time, indirect savings by getting the tank back in-service and reduces risk of confined entry by minimizing the time doing the inspection. Such developments include minimising setup time using software driven inspection plans, having onboard LED lighting system, a paperless reporting strategy that will include assisted defect recognition and minimised deadzones to maximise floor coverage.

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Expanding the Boundaries of X-ray CT: Imaging at Sub-Micron Resolution

Presenting author(s): Dr Herminso Villarraga-Gomez

Co-Authors:

Room: Virtual Room | 5:30 PM Wednesday, November 11, 2020

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NDT 4.0

Presenting author(s): Dr Roman Gr Maev

Co-Authors:

Room: Virtual Room | 10:00 AM Thursday, November 12, 2020

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Leading a Team

Presenting author(s): Ms Julia Tovar

Co-Authors:

Room: Virtual Room | 10:00 AM Thursday, November 12, 2020

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New International Standards in Innovation Management – ISO 56000: What does it mean to the NDE 4.0 Community?

Presenting author(s): Dr Ripudaman Singh

Co-Authors:

Room: Virtual Room | 10:30 AM Thursday, November 12, 2020

An NDE organization’s capability to innovate is a key factor for sustained growth, economic viability, increased system safety, inspector well-being, and sustainability of the infrastructure at large. By definition, this includes the ability to understand and agility to respond, to the changing market conditions, pursue new opportunities, and leverage the knowledge & creativity of people within the organization, and interested network. In Dec 2013, ISO kicked off TC 279 in Paris, and defined their scope as "Standardization of terminology, tools, methods and interactions between relevant parties to enable innovation". Since then, it has been meeting twice a year, reaching over 75 participants from 45 countries in Stockholm meeting. As of October 2019, three out of eight planned standards have been published and others will follow soon. This ISO 56000 series of standards brings best practices in innovation management to everyone. They help organizations identify the need for innovation, the risks and benefits associated, develop a capability to innovate, collaborate, and successfully bring innovations to market. Indeed, ISO 56002 is an overarching document, giving key insights to establish an innovation management system: (a) Understanding the context of the organization, (b) Establishing the leadership and commitment of top management; (c) Planning for innovation development; (d) Identifying and fostering innovation enablers/driving factors; (e) Deploying the innovation management process; (f) Understanding and using innovation management tools and methods; (g) Spread Innovation culture; and (h) Assessing the performance of the Innovation Management System. As ISO 56000 does not contain any requirement and has not been imposed through certification process. It’s adoption will show the relevance for organizations, demonstrating a major change in the way to develop and spread ISO standards. This type of standard and guidance also makes dealing with standard based on self-assessment and management all the more important. Indeed, the result of the self-assessment will guide the organization in the implementation and improvement of its own innovation practices and culture. This makes ISO 56000 very different from Quality Management System (ISO 9000) and NDT Qualification and Certification (ISO 9712). NDE research community can significantly benefit from awareness of these standards as well as intricacies of its implementation. The speaker is currently serving US TAG for ISO/TC-279 focused on developing ISO 56000 on Innovation Management. Over the past few ASNT conferences, he has brought out a few aspects of innovation management in support of NDE 4.0. Many of the elements of his approach to innovation have now found a place in this ISO standard. The proposed presentation will cover what the published standards look like, a flavor of work in progress; and its value to NDE research community.

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Panel Discussion: Leadership and Development

Presenting author(s): Mrs Jennifer AnayaDr Hoda AzariMs Antionette Y BaileyMrs Kimberley A HayesMs Julia Tovar

Co-Authors:

Room: Virtual Room | 10:30 AM Thursday, November 12, 2020

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NDE 4.0 Global efforts

Presenting author(s): Dr Johannes L Vrana

Co-Authors:

Room: Virtual Room | 11:30 AM Thursday, November 12, 2020

This will be an open forum Where national leaders would share the NDE 4.0 activities in their respective countries - USA, Europe, Mexico, UK, … more  

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Effective Communication

Presenting author(s): Mrs Kimberley A Hayes

Co-Authors:

Room: Digitell - Virtual | 11:30 AM Thursday, November 12, 2020

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Robotic Non-Destructive Inspection of Aircraft Composites

Presenting author(s): Dr Adam Brant

Co-Authors:

Room: Virtual Room | 12:00 PM Thursday, November 12, 2020

RE2 Robotics and its research partners has developed a novel technology for autonomous Non-Destructive Inspection (NDI) of aircraft composites. The system can utilize a variety of sensors, such as ultrasonic or terahertz sensors, combined with precise sensor automation and navigation to perform rapid and precise NDI of aircraft composite materials in hard-to-access areas of an aircraft. This solution has been shown to provide levels of precision and fidelity that are 5 to 10 times greater than is available from typical Commercial-Off-The-Shelf (COTS) ultrasound NDI solutions. RE2 adds value to this capability by providing an autonomous manipulator and an intuitive human robot interface, enabling full autonomy and precise physical coverage of the exterior and interior of the aircraft being inspected. The system fuses computer vision and machine learning algorithms with the lightweight and portable Sapien 7 Degree of Freedom (DOF) autonomous manipulator system that can be implemented in multiple different ways, including mounting it directly onto aircraft surfaces. The solution’s data-driven, ruggedized, portable NDI capability will lead to reduced overall operational costs and increased productivity, while also realizing immediate decreases in man-hour costs and maintenance action expenses. Furthermore, due to a high degree of resolution, this solution will help enable data driven predictive maintenance by capturing localized geo-referenced data, enabling maintainers to avoid unnecessary maintenance actions due to schedule-based maintenance practices or false positives. This is particularly important when measuring composite bondline health. Future generations will be able to inspect Barely Visible Impact Damage (BVID) on the composite materials of entire aircraft as well. RE2 Robotics is a leading robotics developer for the U.S. Military, specializing in integrating autonomous, mobile manipulation solutions for multiple application areas, including a strong presence in both the aviation and defense sectors. With support of its R&D team, RE2’s exceptional autonomy, manipulation, and sensing hardware and software for NDI of aircraft composites with leading edge resolution and autonomy capabilities are being realized.

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NDT Technical Writing

Presenting author(s): Ms Antionette Y Bailey

Co-Authors:

Room: Virtual Room | 12:00 PM Thursday, November 12, 2020

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Preventing Casting Defects and Optimizing Foundry Performance Using X-ray Big Data Analytics

Presenting author(s): Mr Gary Ruff

Co-Authors: Mr Michael Keeley

Room: Virtual Room | 12:30 PM Thursday, November 12, 2020

X-ray analyses are traditionally used by foundries to inspect for and detect unacceptable defects such that only high-quality castings are supplied to the end-customer. However, with the advent of new, advanced x-ray technologies in combination with sophisticated techniques for “Big Data” analysis, it is now possible to proactively prevent defects from occurring and allow for foundry processes to be optimized for greater throughput of good parts. This forward-thinking approach to Foundry 4.0, is best applied during the early stages of product development, involves rapidly investigating all anomalies in a casting using digital x-ray radiography and classifying them numerically into various categories such as type, size, shape, distribution and location. At the same time, relevant process parameters are collected for each casting including pouring and mold temperatures, fill times, pressure curves, cycle times, and mold cooling. This information is linked to the x-ray data on a part-by-part basis to establish a large database which is assessed using a variety of statistical and Big Data analytics developed specifically for applications such as this. The desired result is a numerical model capable of predicting under what process conditions anomalies occur and if they are within accepted limits. Defects can therefore be prevented, and products optimized, by specifying and controlling casting parameters using closed-loop data analytics. The benefits of using this approach include: • Defect prevention at the onset of a program results in more efficient, lower cost, and quicker product launches • Process optimization using data analytics leads to the selection and application of the most meaningful casting specifications, as well as reduced operating costs through the elimination of wasted activity and over-control • Use of x-ray/process data analytics models provide a means of continuous improvement of both the part and casting process on an ongoing basis

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9 tips to optimize your online engagement and generate business

Presenting author(s): Ms Veronique Chayer

Co-Authors:

Room: Virtual Room | 12:30 PM Thursday, November 12, 2020

There has been a significant shift towards digital assets in past years but the past few months have proven that simply having an online presence is not enough. In a time where (almost) everything went digital, a good strategy is necessary to make sure that your company stands out among this now very crowded space. In this session, discover 9 tips to optimize online engagement and generate business directly linked with your online presence.

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Fatigue crack measurement based on information entropy of acoustic emission signals

Presenting author(s): Mr Seyed Foad Karimian

Co-Authors:

Room: Virtual Room | 2:30 PM Thursday, November 12, 2020

Fatigue crack detection and measurement play an important role in the remaining useful life (RUL) estimation of sensitive structures. The current use of non-destructive testing (NDT) methods are usually limited to out-of-service inspections and measurements. The ability to detect structural changes resulting from redistribution of the stress of components while in-service makes acoustic emission (AE) a desirable NDT method for structural health monitoring (SHM). However, current approaches in AE signal analysis are based on threshold-dependent features such as count and energy that limit their usage. This research examines the potential of using a threshold-independent measure of AE signals based on the information content of the signals. The histogram of AE signals is studied to measure the Shannon information entropy. Cumulative information entropy of signals from two independent sensors placed in close vicinity of a crack is compared to two conventional threshold-dependent AE features. It is found that compared to cumulative energy and cumulative count, cumulative AE information entropy is less spatially dependent. The cumulative information entropy is shown to correlate well with crack length. This method provides a novel approach to measure the crack length in AA7075-T6 material, using AE as a well-known spatial and threshold-independent NDT technique.

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Artificial Intelligence Approaches to Facilitate Data Analysis of Heat Exchanger Tubes

Presenting author(s): Ms Andreanne Potvin

Co-Authors: Mr Marc Grenier, Mr Florian Hardy

Room: Virtual Room | 3:00 PM Thursday, November 12, 2020

The non-destructive testing (NDT) industry is facing a growing shortage of workers operating in the field of heat exchanger tube inspection, especially level 2 operators capable of analyzing the acquired data. With the regular addition of improved technologies and the transition to an array probe configuration, the complexity of the task and the volume of data continues to grow. More than ever, the industry needs tools to simplify data interpretation and increase analyst efficiency while maintaining a consistent and repeatable level of reliability. Assisted analysis for tube testing with an electromagnetic technique has existed for several years. However, most solutions described in the literature or that are commercially available have been developed for the eddy current technique applied to steam generator tube inspection. There are not many solutions that can support other electromagnetic techniques such as RFT, NFT and array probe in general. Traditional detection methods based on phase angle, amplitude threshold, and probe position in the tube quickly become limited when test conditions are not well controlled (uneven pulling speed, incomplete tube scan, no encoder position) or when information about the tube bundle is incomplete (unknown detailed landmark table, re-tube section). Unfortunately, these test conditions are very common outside the nuclear industry, and they contribute to reducing the efficiency and reliability of data interpretation. This paper explores the feasibility of employing artificial intelligence techniques, such as deep learning, to improve various tasks of the tube inspection process. This includes landmark localization without detailed prior knowledge of the bundle configuration and support for classification of critical tubes to be reviewed by an analyst. Typical implementation results will be presented for ECT and RFT inspection techniques.

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A Structured Method for Collecting Quality Data and Focusing Improvement Initiatives for Greatest Impact

Presenting author(s): Mr Tashreef R Baksh

Co-Authors: Mr Josh Laase, Mr Mike Brown

Room: Virtual Room | 3:30 PM Thursday, November 12, 2020

This presentation focuses on improving the ability of an organization to make effective process decisions by gaining increased visibility across multiple jobs, inspections, and facility locations. A structured methodology is key to establishing an efficient inspection management program that allows identifying trends, mining data for critical factors and failure patterns (weld reject rates, welder performance, material issues, coatings, mill performance), and focusing quality efforts where they make the biggest impact. Organizations sometimes take a “checkbox” approach to quality control, collecting inspection reports and never again referring to them unless there is a problem. A standardized inspection reporting methodology is presented that enables easy report comparison and trending, as well as generation of key performance indicators. The standardized method enables guided information entry, yielding usable, analyzable data. The data provides insight into activities performed, as opposed to after-the-fact nonconformance and corrective action processes. Increased visibility (proactive monitoring) is key to having a robust and effective inspection management program.

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Open Configuration Portable X-ray Computed Tomography

Presenting author(s): Dr Joseph Tobias Case

Co-Authors: Dr Shant Kenderian, Dr Eric C Johnson

Room: Virtual Room | 4:30 PM Thursday, November 12, 2020

X-ray computed tomography (CT) is the standard for volumetric inspection. However, it suffers from the limitation that the part or specimen under inspection is typically placed into a stationary cabinet or ring for which the x-ray source and detector are rotated. Thousands of x-ray shots are acquired at unique angles of incidence, which are subsequently processed to reconstruct a volume image of the specimen. The volume is then rendered or sliced for analysis. Obviously, not all parts are conducive to be placed in a cabinet or ring. Furthermore, it may be desired to inspect only a small region of interest on large parts. For such parts encountered in the field, only a limited number of unique angles of incidence are reasonable or possible when acquiring x-ray shots. Improved x-ray shot acquisition and reconstruction processes are desired to be able to reconstruct volume images from limited shots. Such a system may be lightweight and flexible in order to support an open configuration where arbitrary positioning of the x-ray source and detector are possible. Unfortunately, such an acquisition system may encounter positional and orientation inaccuracy. Therefore, the reconstruction process should also take these into account. Lastly, the reconstruction process should be available in the field; that is, computation resources must be small and lightweight. Thus, it is required that the system exploit small and lightweight high performance computing (HPC) resources like graphics processing units (GPUs) or co-processors. This work describes preliminary results into a prototype system that attempts to solve the above-mentioned problems: limited shots, lightweight x-ray source and detector positioning, and efficient use of small-footprint computational hardware.

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Computer Assisted Hybrid Eddy Current Technology for Rapid NDI

Presenting author(s): Mr Michael S Squillante

Co-Authors:

Room: Virtual Room | 5:00 PM Thursday, November 12, 2020

Timely maintenance of aircraft structures is critical to keeping our armed forces aircraft fleet operational. Defects greatly impact the stability and integrity of the aircraft and, if left undetected, can result in extended removal of the aircraft from service. Since most of the defects and fractures occur beneath the paint or are hidden beneath one or more layers, visual inspection is insufficient. The present method of inspection of aircraft requires redundant scans and intensive human interaction. A faster and more efficient way to perform NDI is necessary to decrease the cost of maintenance and the downtime of each aircraft, while also increasing autonomy during the process. RMD has addressed this by developing a Computer Assisted Maintenance system that employs a hybrid Eddy Current-based scanning technology. This hybrid technology promises to reduce the inspection time to one half to one quarter of the time presently needed to inspect an airplane. This system will have higher sensitivity than traditional EC methods, and scan multiple frequencies simultaneously. Our Computer Assisted Maintenance system will also reduce total inspection time by automating several processes, including defect detection, analysis, and report generation. Machine learning will be used to quickly classify flaws and areas of interest using a novel multi-pass method of inspection . The Hybrid-ECT system that RMD has developed for this application is a breakthrough in Non-Destructive Inspection, which uses RMD’s novel sensing technology along with existing commercial off the shelf components. The technology can be used for a variety of NDI procedures on both military and commercial aircraft.

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Thermal effects on the performance of frequency selective surface based strain sensor

Presenting author(s): Ms Swathi Muthyala Ramesh

Co-Authors:

Room: Virtual Room | 5:30 PM Thursday, November 12, 2020

Frequency selective surfaces (FSS) are a periodic array of conductive elements or patches located on a dielectric substrate. FSSs can act as spatial filters of electromagnetic energy and have specific transmission and reflection properties related to the element geometry/spacing, substrate, and the local (to the FSS) environment. As such, capitalizing on these dependencies render FSSs a good candidate for wireless and remote sensors. To this end, FSS-based sensors have shown potential as a wireless solution for structural health monitoring applications such as strain sensing, temperature sensing, detection of delamination/disbond in layered structures, etc. However, when utilizing FSSs for sensing applications, it is important to understand the effect of internal (to the sensor) parameters such as the thermal response (expansion) of the substrate and conductive element materials on the measured sensor response. In this way, if the sensing environment undergoes a thermal change, the error introduced in the sensor response while measuring an external parameter (i.e., the quantity of interest such as strain) will be a priori known and can be removed. Similar concerns arise when other environmental parameters such as humidity are considered in the case of hygroscopic sensor materials, as the absorption of moisture into the sensor substrate will also have an unintended effect on the measured sensor response. To this end, this work reports on the effect of thermal expansion and hygroscopicity of patch and loop-based FSS sensors constructed of commercially available sensor materials. Representative simulated results will be provided, and the error on the sensor response quantified.

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