Radiographic Sensitivity of Selenium versus Iridium Radioisotopes for Digital Detector Array and Computed Radiography Systems

Presenting author(s): Mr Brian S White

Co-Authors:

Room: Pavilion 9 | 10:30 AM Tuesday, November 19, 2019

Radiographic sensitivity was determined for Selenium and Iridium radioisotopes used in combination with computed radiography and digital detector array radiography systems. Steel and aluminum plates with a range of penetrameter thicknesses were utilized to determine the point at which sensitivity could be achieved. Detectability improved with Selenium relative to Iridium across all conditions due to lower noise. Likewise, detectability improved with digital detector array radiography systems relative to computed radiography systems. Data from this investigation, as well as corresponding practical images, will be presented as part of this paper.

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Introduction to Leak Testing

Presenting author(s): Mr Michael V McGloin

Co-Authors:

Room: Pavilion 10 | 10:30 AM Tuesday, November 19, 2019

The purpose of this talk is to introduce the attendee to the Leak Testing method.  The talk will review the basic principals in which Leak Testing works, as well as, applications that Leak Testing can be applied to in addition to some of the limitations of the Leak Testing method. The primary focus will be on the four techniques listed in SNT-TC-1A, which are: Bubble, Pressure Change, Halogen Diode, and Mass Spectrometer.

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Development and Field Deployment of a Motorized Retrieval Tool with Integral HDTV For Power Plant Applications

Presenting author(s): Mr Bruce A Pellegrino

Co-Authors:

Room: Pavilion 11 | 10:30 AM Tuesday, November 19, 2019

Even with the best of FME (foreign material exclusion) safeguards, accidents still happen and often at the worst times, impacting lost time, safety, and/or production. Foreign materials are accidentally introduced into critical assets during scheduled or forced outages. Mechanical breakdown of components can also contribute to the introduction of foreign materials, without human elements. Jaws 2.0 builds on Sensor Network’s success in making robust motorized retrieval tools designed to remove foreign materials, safely and quickly. A key design consideration was size, so the tool was reduced to 1.5” in diameter. Jaws adds vision to a portable tool with the addition of an integral 1080p HD camera and LED illumination. Seeing greatly enhances retrieving. Of significant value is the multitude of various end-effectors to facilitate the removal of everything from rags, hardhats, flashlights, screws, pens, and even cell phones. The Ultimate kit includes hooks, snares, magnets, claws, delivery adapters, and interconnecting fiberglass pushrods. All are designed to operate submersed to 100 ft. In nuclear applications the camera has been tested to failure at 30,000 total cumulative rad. The tool and controller is powered by a rechargeable NiMH battery or AC. Tool head weight is 1.2 lbs. and clamping force is 25 lbs. Patents are pending and field testing is being performed at many nuclear plants.

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Impact of Collimation on Line Scan X-Ray Images

Presenting author(s): Ms Julie Yang

Co-Authors:

Room: Pavilion 9 | 11:00 AM Tuesday, November 19, 2019

Various methods and techniques are used in the x-ray industry to improve imaging quality of line scan x-ray detectors: increasing x-ray power, increasing the dynamic range of the imaging sensor, using longer integration time, etc. Other methods also include mechanical design alternatives such as optimized x-ray acceptance angles, sufficient shielding and radiation scatter guards, and collimation inside and outside the detector housing. This presentation will focus on the more economical way of improving imaging quality of line scan x-ray detectors: sensor side collimation. By simply placing two pieces of high-Z metal plates strategically above the sensor boards, imaging quality can be improved greatly in terms of crosstalk reduction and contrast sensitivity elevation.

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NASA-STD-7012 Leak Test Requirements: Potential Reference for ASNT Nondestructive Testing Handbook Leak Testing

Presenting author(s): Dr Oleg M Lvovsky

Co-Authors:

Room: Pavilion 10 | 11:00 AM Tuesday, November 19, 2019

Developed in 2018-2019, NASA-STD-7012 Leak Test Requirements, has been drafted based mostly on the NASA technical requirement documents applicable to the International Space Station (ISS) hardware and payloads that were developed over the years taking into consideration many known references such as Leakage Testing Handbook prepared by General Electric for the Jet Propulsion Laboratory, the ASTM International standards for leak testing, and last, but not least, the ASNT Nondestructive Testing Handbook for Leak Testing. Thus, NASA-STD-7012 has a reference to the above-mentioned handbook in the leak test method/technique descriptions. However, there are some technical details that are described differently in NASA standard and ASNT Handbook. Those technical details are mostly related to the classification of the leak test methods/techniques, and also to tracer gas to working fluid (gas or liquid) leakage rate conversion methodology, and to some definitions used in the text of both NASA standard and ASNT Handbook. Those differences are going to be briefly described in this paper to let ASNT leak test experts decide if they want to refer to NASA-STD-7012 while working on the next edition of the ASNT Handbook, Volume 2 for Leak Testing. 
Keywords: leak test, leakage rate, sensitivity

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Irradiation Behavior of Piezoelectric Materials for Nuclear Reactor Sensors

Presenting author(s): Mr Gaofeng Sha »

Co-Authors:

Room: Pavilion 11 | 11:00 AM Tuesday, November 19, 2019

Piezoelectric materials are the key element of many electronic communication and advanced sensing technologies, such as ultrasonic transducers, surface acoustic wave filters and micro-electromechanical systems (MEMS), and are also attractive for nuclear instrumentation. One potential limitation for their applications in nuclear instrumentation is degradation of physical properties upon accumulation of radiation damage caused by neutron or energetic particles. Irradiation behavior of integrated ultrasonic transducers in a nuclear reactor has been previously demonstrated. However, the radiation impact on a piezoelectric crystal itself has not been extensively studied. The focus of current study is to investigate the impact of neutron irradiation on piezoelectric properties. Technically, surface acoustic wave (SAW) sensors based on interdigital transducer architecture has been identified to perform in situ measurements of various piezoelectric materials in a nuclear reactor. In this presentation, we will summarize the recent progresses in experimental study aiming to understand the irradiation behavior of piezoelectric materials such as lithium niobate and aluminum nitride. Specifically, we demonstrate how changes in the frequency response of a SAW device during neutron irradiation can be related to intrinsic piezoelectric, elastic, and dielectric constants of the piezoelectric material.

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Convolutional Neural Networks Applied to The Automatic Detection of Welded Joints and Fraud Prevention

Presenting author(s): Mr Thiago Jose Da Silva

Co-Authors: Mr Ed Bassoli, Mr Edgar Gadbem, Joao Herrera, Mr Juliana Mariana Macedo Araujo, Mr Hugo Augusto Alves

Room: Pavilion 9 | 1:30 PM Tuesday, November 19, 2019

The inspection of radiographic images of welded joints in pipelines at oil and gas industry is a normative security item. Such analysis is crucial, as long as only pipelines with approved welds may be operated. In this context the presence of duplicated radiographs, which means a radiography taken for the same weld and indicated as a different joint, can put at risk the safety of the whole surrounding installation. This may occur unintentionally due to misleading action or intentionally due to improper conduct when the professional responsible for the inspection does not follow strictly technical standards letting economical aspects surpass with unique purpose of rapidly conclusion of the inspection and improper costs reduction. Therefore, in this paper we propose a novel approach to segment welded joints using Convolutional Neural Networks and compare them for fraud detection. The comparison is performed inside the weld region through keypoints detection, which is applied to recognize residual edge details emphasized by preprocessing techniques. Most similar regions have their associated coordinates used to iteratively align both images and compute a score that predicts how similar are their welds. Our results shows an accuracy of 94.48% using a dataset with 119 annotated images and 35 welds. To reduce its quadratic complexity we also propose a Fuzzy clustering based on K-Means algorithm to avoid comparison among welds with dissimilar features.

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Is NDT Engineer a demand of Industries? What would be the requirement and who would provide the degree?

Presenting author(s): Mr Mirmajid Ghaemi

Co-Authors:

Room: Pavilion 10 | 1:30 PM Tuesday, November 19, 2019

Since many years there was a discussion what is the demand of industries for NDT specialists to lead the NDT activities ? What academic education is sufficient ? NDT application is considered as a technical profession that needs some level of education on physics , material science , production process plus a certain limit of practice and experience . By this approach an NDT specialist who is needed in different industries to lead and execute NDT activities are trained and certified beyond of the university courses . Usually NDT is not considered as an Academic degree that would be educated in university to be able to fulfil the requirements in industries . So far NDT specialists needed a limited academic education . Since many years Academic NDT education in Master level is presented by some universities in USA and Europe but their focus was providing qualified graduates to perform R&D programs in Research Centers or Universities . The graduates from such universities are educated but not certified that needs practice & experience that is also the requirements of all industries . From the other side the demand in such academic level is limited . Dresden International university ( DIU )/ Germany has started MS courses since 2013 . DIU is providing a new 4 semesters program in cooperation with German NDT Society( DGZFP ) and German Research Institutes . As DIU program the students are prepared to obtain Level 3 by DGZFP or as a Researcher by a Research Center. Despite of no need to have university degree to get Level 3 certification according to the all Standards but a brief study indicates that most of successful Level 3 specialists in different industries possessing engineering degree . Most of the Level 3 NDT specialists are engineers who follow the training , qualification and Certification process to be certified as a LEVEL III after educating from the university . This is a current successful practice . But Since some years due to entering sophisticated techniques and high technologies as well as computer science in NDT principles there is an idea to train an NDT engineer in universities in BS. degree to fill a gap that seems industries encountering with that. The other point that is also under discussion is the number of methods and the time length of experience that a Level 3 certificate holder posses Currently having a fresh certificate in one level is recognized a “ level 3 Specialists “ while a qualified specialist to be able to lead all NDT activities needs to be certified in multi methods as well as some years of experience . Would such specialists be recognized as “ NDT Engineer “ ? What standard or organization would be eligible for such recognition ? Currently the issue is under discussion in ISO , ICNDT and National NDT societies like ASNT . In this paper different attitudes are discussed and evaluated to open a new window for further discussions . *

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Improving Process Control in Magnetic Particle Inspections

Presenting author(s): Ms Alex Anne Mastroni

Co-Authors:

Room: Pavilion 11 | 1:30 PM Tuesday, November 19, 2019

Improve NDT process control and efficiency by providing traceability for parts, jobs, customers, operators, and more. Electronic reporting reduces dependency on manual recording keeping for safer, more reliable trackability of Nadcap audit criteria and other compliance requirements.

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The Phase Contrast Radiographic Imagining

Presenting author(s): Dr Bahman Zoofan

Co-Authors:

Room: Pavilion 9 | 2:00 PM Tuesday, November 19, 2019

The concept of new enhanced phase-contrast radiographic imaging by using micro-focus X-ray tubes is discussed in this presentation. In conventional radiography the X-ray beams which penetrate through a specimen are partially absorbed based on the object thickness or attenuation of the material under test. The technique shows inherent contrast limitation for specimens containing low-density internal structures or in the case of very thin objects. An alternative approach to overcome this limitation in absorption radiography is to apply the phase-contrast imaging technique. The key element to this technique is using high spatial resolution of X-ray beam emitted by micro-focus tubes compared to conventional radiographic systems. The phase-contrast imaging enables one to record the variation in the phase of the passing X-ray beams to enhance the obtained image for parts having low absorbent materials. The change in phase of the spatial resolution X-ray beams, similar to light, leads to a minor change of the path of the X-rays as they reach any physical density changes in a specimen. The physical principles of the phase contrast technique are similar to those in optics and are based on X-ray interference. Most prior research on phase contrast imaging has been done on biological tissues and for medical research. It can be shown that the technique can be successfully applied to low absorbent samples in an industrial set-up, demonstrating significant enhancement. Optimization of the experimental set up and radiographic parameters to achieve phase-contrast images are described in this presentation. Modeling and experimental aspects of the phase contrast technique with a micro-focus X-ray source and the effects of geometrical and material parameters are reviewed in some detail.

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NDT Training for The Next Generation

Presenting author(s): Mr Donald D Locke

Co-Authors:

Room: Pavilion 10 | 2:00 PM Tuesday, November 19, 2019

Training and education as a foundation for any career is nothing new. Training and Education in NDT has not changed a great deal in my 46+ years in the field. Adjusting teaching methods and understanding the next generation is the challenge and this presentation will address what is happening and what is planned in the future for this topic. This discussion will include personal training, formal training, mentoring, measurement of skill, and continuous improvement and measurement. Examples of training from 1972-1996 USAF Military , 1996-2006 Engineering Market, 2006-2008 Junior College Market, 2008-2019 Professional NDT training market. Attendees can learn of the need for flexible and challenging leadership and mentoring in addition to better listening skills as new NDT techs and engineers take on 2020 challenges. NDE 4.0 will be a thing of the past soon and the challenge to stay informed about new technology will continue to be a concern for NDT instructors and level IIIs. This paper will remind attendees of past challenges and success and also openly highlight new challenge with technology and the future NDT technician.

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Benefits of Renewing MT Oil Carrier

Presenting author(s): Mr Michael A Kowatch

Co-Authors:

Room: Pavilion 11 | 2:00 PM Tuesday, November 19, 2019

For as long as carrier fluid has been used for MPI examinations, it has been disposed of once the contamination level gets too high, but now there is an alternative... renewing carrier fluid. There is a new product now available that allows users of carrier fluid to renew (clean), versus disposing of, their carrier fluid. This process allows carrier fluid to be renewed multiple times therefore, a single tank of fluid can be used for many years. Although the financial impact is obvious, the environmental benefits are also extremely important to many companies. This simple, relatively inexpensive process will forever change how we handle carrier fluid.

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Design and Characteristics of Microfocus X-ray Source having a Sealed X-ray Tube with Transmissive Target on Diamond Window and Its Use for Industrial Non-Destructive Inspection

Presenting author(s): Mr Takaaki Tsunoda

Co-Authors: Mr Takeo Tsukamoto

Room: Pavilion 9 | 2:30 PM Tuesday, November 19, 2019

Electronic devices such as medical instruments implanted in human body and Electronic Control Units (ECU) in automobiles or airplanes have a large impact on human life and the electronic circuits in these devices require highly reliable operation. X-ray non-destructive inspection has recently been in strong demand as one way to help ensure high reliability. Companies who use high density packages for micrometer-scale circuits or Lithium ion batteries require high-speed, high-magnification inspection of all parts and our company has developed a new X-ray source supporting these requirements. Our X-ray source has a sealed tube with transmissive target on a diamond window that offers advantages over X-ray sources having sealed tube with a reflective target. Our transmissive X-Ray source has been recently developed to provide high output power with a longer shelf life and degradation-free anode. In this paper we will summarize X-ray source classification relevant to electronic device inspection and will detail X-ray source performance requirements and challenges. We will also elaborate on technologies employed in our newly developed X-ray source including X-ray tube design implementations for; (1) High resolution and high output power simultaneously for high speed inspection, (2) High output power at high magnification for micrometer-scale electronic device inspection, (3) Reduced system downtime for automated X-ray inspection system and (4) Reduced X-ray dose utilizing pulsed X-ray radiation mode for protection of sensitive electronic device.

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Strengthening of NDT Industrial Application Methods and Consolidation of the National Training Center in Albania

Presenting author(s): Dr Esmeralda Vataj

Co-Authors: Mr Patrick Brissett, Dr Ralf Holstein, Blerina Papajani

Room: Pavilion 10 | 2:30 PM Tuesday, November 19, 2019

The use of Non-destructive testing methods in Albania begins in 1965 with the creation of the Industrial Assembling Enterprise (IAE). The first NDT lab was created in IAE. In addition to IAE there were created 2 other groups of NDT: - Chemical Fertilizer Factory (CFF), Fier - Oil Refinery (OR), Ballsh. From 1999 the Albanian industry activities begin to reactivate and therefore in the country the necessity for NDT analyses increased. Different NDT companies are operating today in the Albanian market. The main development aiming of the Albania region are hydropower plants, oil and gas industry. To support these industrial developments are required professional workers with knowledge in structural integrity testing and evaluation (such pipelines, pressure vessels, storage tankers, turbine pipelines). Presently, there was no formal training program in the country for personnel directly involved in such technologies and stakeholders being potential end-users. Therefore, in-order to promote the use and practice of monitoring and testing technologies as a service tool in the country, but also to develop awareness and research and development activities, it was necessary to establish a National Training Center according to ISO 9712 standard. The creation of the national training center was supported by International Atomic Energy Agency (IAEA) within the framework of Technical Cooperation programs. In this paper are described: NDT Business in Albania figures and challenges; development of the training facility from point zero: equipment, trainers, scheme, customers; integration of NDT syllabi in university curricula.

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Sustainability Improvements in Magnetic Particle and Penetrant Testing

Presenting author(s): Mr Kersten Alward

Co-Authors:

Room: Pavilion 11 | 2:30 PM Tuesday, November 19, 2019

Supervisors using MT and PT-consumables in their area of responsibility are well advised to consider the use of chemicals with the lowest possible impact to the work safety, the environment and the overall process costs. The REACH-legislation is fully in force and the new labelling regulation CLP has to be applied as well and brings an additional pressure to this situation. Leading manufacturers of NDT consumables have modified their products in order to match these requests without influencing the technical performance. For the sake of the work safety more and more products are free of hazardous ingredients and therefore free of any hazard labeling. Completely biodegradable products and a carbon footprint evaluation of widely used NDT consumables help to optimize the environmental impact. Several measures can reduce substantially the NDT process costs. This enables the users of magnetic particle and penetrant testing consumables to make decisions not only based on purchasing costs. The improvement of the work safety and the environment protection can now be taken into consideration better than ever before. For standards-compliant and future-save NDT processes.

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DR Advancements and a Common-Sense Approach to Streamlining System Qualification and Process Controls

Presenting author(s): Mr Camaron Lemmer

Co-Authors:

Room: Pavilion 9 | 3:00 PM Tuesday, November 19, 2019

Digital Radiography (DR) technologies and techniques continue to push performance to new levels in both image quality and speed. These advancements provide new application opportunities as well as methods of substantially reducing cycle times in production environments. Continued innovations in product handling as well as fully integrated robotics even further streamline product flow. Advancements in software is helping with the integration of industry 4.0. In this presentation we will provide examples of the above, as well as proven methods of qualifying DR systems and techniques, while simplifying the implementation of industry required process controls.

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Certification Issues Related to Application Of TC 1A

Presenting author(s): Mr Sebastian Zeferino Fernandes

Co-Authors:

Room: Pavilion 10 | 3:00 PM Tuesday, November 19, 2019

The intent of this presentation is to increase awareness so that competent and properly certified personnel will be engaged for conducting inspection on their assets. Over the past several years, personnel bearing NDT Level II (two) Certificates have surfaced who have been found to be incompetent in the application of the Test Method and use of related equipment. SNT TC-1A, Personnel Qualification and Certification in Nondestructive Testing, is a document established by ASNT that provides guidelines for employers to establish a in-house certification program for nondestructive examination. personnel. This system has been widely used worldwide by employers since 1966. This recommended practice helps ensure a minimum level of competency for NDT practitioners and applies to NDT methods used by them. The program is supposed to be administered by the employer to ensure that the people he has engaged for conducting nondestructive testing are adequately qualified and consequently certified for the record SNT TC 1A indicates the minimum qualification requirements in terms of Education, Training, Skills and Work Experience for certifications to Three Levels of competence - Operator Level -Level I , Inspector/Supervisor level - Level II and Expert Level - Level III A related document, CP 105 details the recommended Training curricula to be followed during the training delivery. The employer is required to ensure that the concerned individual is completely knowledgeable about the test method fully competent in operation of applicable equipment, has adequate product knowledge of the item to be tested and is competent to properly evaluate the test results. Properly trained and qualified individuals will be able to correctly assess the quality of assets being manufactured and installed at Owners facilities and at sub-contractor's sites and increase reliability of testing and emphasizing ASNT motto "Creating a safer world" Additional Information: The UAE section of ASNT has established a Certification Oversight Committee and is committed to weed out this problem at least in UAE and possibly in the Middle East Region. The Author is a member of the Board of Directors at ASNT (USA) and member of the Certification Management Council. He has in excess of 40 years of industrial experience and bears several professional certifications

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High-Throughput Magnetic Particle and Dye-Penetrant Testing Systems for Automotive, Railway and Energy Industries

Presenting author(s): Mr Kirill Zilberberg

Co-Authors:

Room: Pavilion 11 | 3:00 PM Tuesday, November 19, 2019

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Insites on CT system Selection

Presenting author(s): Mr Gregory Budner

Co-Authors:

Room: Pavilion 9 | 4:00 PM Tuesday, November 19, 2019

The requirements for a computed tomography system can be selected by knowing the general inspection results that are expected from the CT scan. In a production environment the scan time is mainly determined by the inspection requirements such as resolution, object size and material density. To increase productivity, batches of parts can now be inspected using part changers. The importance of automatic selection of repeatable technique has led to improvements in programing parts changers, x-ray beam quality and resolving power of the system. Selection of the detector and source are important to consider so that the system is as flexible as possible and can provide inspections that meet all the criteria for multiple object scan runs. Better accuracy of multiple scans throughout time in the production environment leads to a decrease in production time and cost as well as an increase in accuracy for metrology and porosity studies. Catalog off-the-shelf systems meet requirements for objects that are dense or larger in size through utilization of linear accelerator technology and high energy detectors. IN-SITU-CT provides solutions for applications that require real time environmental and part stress studies.

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New Applications of Weld Inspection Using Total Focusing Technique

Presenting author(s): Dr Guillaume Neau

Co-Authors: Dr Olivier Roy, Mr Laurent Le Ber

Room: Pavilion 10 | 4:00 PM Tuesday, November 19, 2019

TFM imaging is increasingly recognized in NDT industrial fields for its qualities: realistic images with maximum resolution, facilitating the analysis of results, and easy set up allowing faster and safer inspection work. ASME and IIW teams are working on documents to take into account into Standards the use of FMC/TFM. Despite its qualities, TFM imaging still has to apply the physics of ultrasound to produce the expected images. This paper will present several applications of weld inspection where TFM imaging can be applied with advantages in front PAUT techniques, by using the relevant transducer and the right option for TFM method. As TRL transducers may improve the detection of defect in complex materiale, at chosen depth, the combination of these transducer –linear or matrix- with TFM method produces high quality imaging by gathering all advantages. In case of attenuative material, TFM imaging can be improved by using different transmitting mode, as PWI, to increase sensitivity and detection capability. Several applications and results are presented to illustrate the capabilities of TFM techniques for weld inspection.

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Compressive Strength Evaluation of Lightweight Concrete with Expanded Glass Aggregate by Ultrasonic Pulse Velocity Method

Presenting author(s): Mr Chris Collins

Co-Authors:

Room: Pavilion 11 | 4:00 PM Tuesday, November 19, 2019

In this paper, the non-destructive Ultrasonic Pulse Velocity (UPV) method was used to assess the compressive strength of a variety of lightweight concrete mixtures. Poraver®, the lightweight aggregate of focus for this study, is expanded glass and made from post-consumer recycled glass. The experiment included about 150 specimens and the unit weight for the entire sample size ranged from around 880 to 2300 kg/m3. Specimens were tested on the 7th and 28th day for compressive strengths. The significance of the correlation between the ultrasonic pulse velocity and compressive strength was investigated. These factors included different mix proportions, size, and volume of aggregates, and the replacement of normal weight coarse and fine aggregates with lightweight aggregates. Simplified expressions from literature for the compressive strength and modulus of elasticity for lightweight concrete was presented for concrete with similar materials and mix designs. Furthermore, the prediction of the concrete’s compressive strength resulting from the ultrasonic pulse velocity test was investigated. The structural efficiency, in terms of UPV and compressive strength, of each concrete mix fabricated was also compared.

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Proposed Phantoms and Methods for Evaluation of Image Quality Metrics for Industrial CT

Presenting author(s): Mr Xin Li

Co-Authors:

Room: Pavilion 9 | 4:30 PM Tuesday, November 19, 2019

Purpose. Detection and measurement accuracy using industrial CT is limited by image quality (IQ). The reconstruction algorithm (recon) is a strong contributor to IQ. Image quality includes spatial resolution, image contrast, and image variations from random noise and artifacts. Artifacts include cupping, shading, and streaks. We propose and assess a method (phantoms and analysis software) designed to measure IQ metrics in industrial CT images. Methods. Five different annular phantoms (4-inch OD; 2-inch ID) were constructed from stainless steel. Each phantom was scanned in an industrial cone-beam CT system at four scatter levels. Images were reconstructed using five recons (filtered backprojection and four advanced recons with different artifact correction and noise suppression methods), producing 100 datasets (5 phantoms, 4 scatter levels, 5 recons). For each dataset, spatial resolution was measured using the edge response function (ERF), its derivative, the point spread function (PSF), and the PSF’s Fourier transform, the modulation transfer function (MTF). Also for each dataset, image contrast (C), random noise (R), and artifact level (A) were computed in relevant regions of interest; from these, total variations (T) and each contrast-to-variation ratio (C/R, C/A, C/T) were computed. Results. All IQ metrics showed trending results for each recon over the 20 phantom/scatter conditions but different results for different recons. PSF full-width-at-half-maximum (FWHM) ranged from 29.7 mils (0.001 inch) to 15.0 mils C/T ranged from 4.3 to 15.9. Conclusion. The proposed method was able to quantitatively evaluate the quality of industrial CT images in terms of spatial resolution, contrast, noise, and artifacts.

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Building TFM Procedures for ERW Hook Cracks, Girth Welds, HTHA, and Other Challenging Inspections

Presenting author(s): Ms Emilie Peloquin

Co-Authors:

Room: Pavilion 10 | 4:30 PM Tuesday, November 19, 2019

Full matrix capture (FMC) and the total focusing method (TFM) have shown improvement in specific applications in the past few years. However, inspectors using this method are still subject to trial and error to achieve good results. Challenges with TFM inspection include selecting a propagation mode to minimize blind spots, confirming the angle of reflection, and optimizing for preferential gain direction. In particular, choosing the most appropriate mode of propagation (i.e., the imaging path) is critical for an effective TFM inspection, and it requires extensive procedure development on simulation software to help ensure proper detectability and perpendicularity of the beams with the reflectors (defects). The acoustic region of influence (AROI) simulator is a theoretical amplitude representation (color map) of the region, mode of propagation, and type of reflector selected. With this tool, multiple imaging paths can be combined to obtain the optimal probability of detection (POD) for a given indication or damage mechanism. In this paper, we describe a wave propagation modeling technique that calculates the predicted signal response in the TFM zone for both pulse-echo and self-tandem modes of propagation. We also highlight how the AROI tool improves challenging inspections, such as identifying hook cracks in electric resistance welding (ERW) where defects can appear parallel to the scanning surface and in high-temperature hydrogen attack (HTHA) where micro-fissuring can occur in different directions and location within the part.

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State-Of-The-Art and Novel Trends in Ultrasonic Imaging of Concrete Structures

Presenting author(s): Mr Andrey Bulavinov

Co-Authors: Mr Roman Pinchuk, Mr Andrey Samokrutov

Room: Pavilion 11 | 4:30 PM Tuesday, November 19, 2019

The novel technologies in ultrasound generation and data processing offer new opportunities for three-dimensional imaging of concrete structures. Especially the Full-Matrix-Capture (FMC) technique with its real-time imaging capability can be successfully used for quality assurance in the construction industry. Although, the available testing instruments on the market implement the principle of linear transducer array with its two-dimensional reconstruction of B-Scan images according to Synthetic Aperture Focusing Technique (SAFT) principle. The Dry-Point-Contact transducers utilized in commercially available instruments for concrete testing with their matrix-like layout offer direct opportunity to implement three-dimensional Full-Matrix-Capture (FMC) data acquisition cycle. The obtained data can be in real-time processed in 3D-SAFT reconstruction and visualization of inspection results. In the present contribution, experimental results of 3D-FMC data processing and visualization performed on real concrete inspection objects are presented and the advantages of true 3D tomography in respect to improved information content and easiness of result interpretation is discussed.

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Multi-energy X-ray Computed Tomography for the Non-destructive Evaluation of Materials

Presenting author(s): Dr Keith Bartels

Co-Authors: Dr Adam Cobb

Room: Pavilion 9 | 5:00 PM Tuesday, November 19, 2019

X-ray Computed Tomography (CT) scanning is a well-established technique that combines X-ray images collected at different angles through a part using a reconstruction algorithm to produce a three-dimensional distribution of the X-ray attenuation. The resulting attenuation is a function of both the mass density and atomic number of the materials. Classical reconstruction algorithms assume the X-ray source is mono-energetic and so artifacts occur with most industrial CT systems which use the broad spectrum produced by an X-ray tube. This paper describes the use of multi-energy CT imaging to reduce or eliminate beam hardening artifacts while at the same time providing extended information about the material(s) being imaged. From a generalized multi-energy procedure, the use of dual-energy CT is used to produce independent measurements of the distribution of two materials is demonstrated. Dual-energy procedures reported previously in medical literature for the identification of materials are extended to the higher-energy case of industrial CT for non-destructive evaluation. Demonstrations of data-driven and model-driven multi-energy imaging processes are given.

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Development of High Sensitivity PAUT Technique for Weld Inspection of UOE Pipe

Presenting author(s): Mr Mitsuru Miyamoto

Co-Authors: Mr Yoshio Ueda, Mr Masaki Yamano, Tomohiro Suzuki, Tsuyoshi Hieda

Room: Pavilion 10 | 5:00 PM Tuesday, November 19, 2019

UOE pipes are widely used for the line pipes transporting various energy fuels and large-scale structures all over the world. Such applications require high quality products because they are always exposed to tough environments. Problems with UOE pipes are often caused by the quality of the weld zone, and inspection of the weld zone is particularly important in the business of UOE pipes. The supplier needs to guarantee the quality of the weld zone, which is achieved by ultrasonic testing. We have developed technology to detect defects in the weld zone by using a phased array technique with full-sectional inspection is conducted. The requirement for the higher strength pipe of the customers, are demanding further severe quality assurance of the weld zone. Therefore, we improved technology to detect defects of the weld zone. In this study, our target is to detect longitudinal defects with high sensitivity in the weld zone, and the phased array probe with high detectability was developed. Improving probe performance is one of the most effective approaches to increase detectability. Specifically, the shape and material of the wedge were improved, and the material of the sound absorber is also improved. The significant improvement of the sensitivity and SN ratio were confirmed by the in-line tests.

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Eddy Current NDT of Reinforcements in Concrete Structures

Presenting author(s): Mr Evan Weststrate

Co-Authors: Mr Michael S Squillante

Room: Pavilion 11 | 5:00 PM Tuesday, November 19, 2019

Improved NDT techniques are needed for the assessment of reinforced concrete in a large variety of structures. Steel embedded within concrete can corrode and crack, leading to weakening of the material, and existing NDT methods may not be able to provide a full picture of the reinforcements during inspection. Condition assessment is critical in evaluating these structures in order to ensure safe, long-term operation of power plants, bridges, parking decks, buildings, and many other forms. These industries use eddy current (EC) testing during in-service inspections to detect and monitor defects such as cracks and corrosion, both internally and on the surface of metals. However, the detection of defects in reinforcing steel embedded in concrete is far more challenging for numerous reasons. Primary among them is the thickness of the concrete around the steel, which prevents the ability to position the sensor in close proximity to the metallic material. A solution to this problem is to create a highly sensitive technique that can penetrate the concrete with good spatial resolution and sensitivity in order to detect, map, and characterize the metal buried deep in the concrete and identify defects in that metal. This work expands on traditional EC techniques by applying them to the inspection of conductive embeds in concrete such as rebar, tensioning strands, pre-stressing wires, reinforcing mesh, and fasteners, which are buried in the generally non-conductive cement and aggregate. This approach utilizes an oscillating driving coil to generate a magnetic field, inducing currents in the metal structure. An array of magnetic sensors detect the perturbations in that field, and the signals are processed and interpreted to generate maps and make condition assessments of the underlying steel structure. The magnetic state of materials have a significant impact on the performance and fidelity of the eddy current signal, and part of this work focuses on methods to process and interpret sensor data responses from scans of ferromagnetic materials. In some cases, this technology has the potential to collect high resolution information about the condition of the material. The system can also provide fast initial evaluation with 0.1 inch resolution structure mapping and speeds above 24 inches/second. This capability will enhance current field inspection and reduce the cost and time required for the evaluation of a variety of structural components.

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Emerging Technologies and Techniques in DR and CT

Presenting author(s): Mr Brett A Muehlhauser

Co-Authors:

Room: Pavilion 9 | 5:30 PM Tuesday, November 19, 2019

New developments in hardware and software have proven to further advance both DR and CT image quality and overall capability. Technique advancements are providing methods of further increasing speed in production environments. CT is rapidly becoming the "Go To" technology for evaluating many aspects of Additive Manufactured products. This presentation will include examples of applying these latest developments across various industries and a wide range of product applications.

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Improvement in The Ultrasonic Examination of Austenitic Steel Weld with PA Using TMC/TMF Integrated Non-Linear Non-Linear Signal Processing

Presenting author(s): Dr Giuseppe Nardoni

Co-Authors: Mr Diego Nardoni, Mr Alessandro Filosi, Mr Stefano Quetti

Room: Pavilion 10 | 5:30 PM Tuesday, November 19, 2019

The new request in high resistant steel at high temperature in the range of 500-1000°C has implemented the use of austenitic steel structure material and consequently the welds. Due to the critical request in the quality of welds the latest technique in PA has been experimented and consequently applied. The new PA technique using TMC and TMF has been experimented on thicknesses of weld from 15mm up to 80 mm. Sensitivity and signal to noise ratio have been evaluated on hole and cracks produced by EDP (electronic data processing). The results are very promising. Signal to noise ratio is very low and the indications appear clearly identifiable.

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Robotic Nondestructive Systems for Inspection of Concrete Structures

Presenting author(s): Mr Sameer Hamoush

Co-Authors:

Room: Pavilion 11 | 5:30 PM Tuesday, November 19, 2019

This paper presents structural inspection of loaded concrete members using robotic nondestructive testing techniques. The hand-held nondestructive test methods are the most common tools to detect the internal defects. Due to accessibility problem, environmental contamination or safety issues, the Robotic NDT plays in indispensable role in health monitoring and inspection of such structures. The robotic systems are develop for a various NDT sensors such as ground Pentation Radar (GPR), Echo Hammer and Portable Seismic Properties Analyzer (PSPA). To develop the techniques, twelve reinforced concrete beams are fabricated in four different groups to simulate the most common types of concrete defects. These groups are control beams; beams with internal void; beams with corroded bars and beams with debonded bars, respectively. Some of the beams have non-uniform thicknesses and others have rough surfaces (honeycombing). These beams are inspected robotically while they are not loaded and then the same beams are inspected while they are loaded under a mainframe MTS system. The purpose of the second inspection is to track the progress of the internal defects. The loaded beams inspection is performed at three loading states, state one is at post cracking, state two is at 0.70 of ultimate load and the third state is at the ultimate load. The outcome of this study shows that the develop Robotic NDT systems can be an effective method to assess the structural conditions of defected concrete members.

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NDE of Rail and Track, a Federal Railroad Administration Perspective

Presenting author(s): Mr Robert Wilson

Co-Authors:

Room: Pavilion 9 | 9:00 AM Wednesday, November 20, 2019

FRA rail and track integrity research efforts are directed towards increasing safety and reliability of rail transportation. Non-destructive evaluation (NDE) plays a vital role in this effort. With nearly 140,000 track miles, which are owned, operated, and maintained by private railroads (Class I, regional, and shortlines) in the North America, it is a daunting task for the railroads and the FRA to ensure all rail and track structures are free of defects and safe for the transportation of goods, hazardous material and people. The railroad NDE task is challenging for several reasons beyond just the enormous scope of it. Some of those additional challenges are rail profile changes due to wear, variability of the rail head surface condition, wide variety of components, debris or ballast covering track components, fastening and boundary condition variability and many more. This presentation will review some of those challenges as well as highlight a few NDE projects the FRA has funded in recent years. In addition, the presentation will cover how the government, railroad industry, organizations, small scale businesses and individuals can work together to advance NDE technology. Finally, potential funding opportunities and technology transfer will be discussed.

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The History of Leak Testing – From “there to Now and Beyond”

Presenting author(s): Mr Todd E Sellmer

Co-Authors:

Room: Pavilion 10 | 9:00 AM Wednesday, November 20, 2019

This paper will discuss the history of leak detection from the earliest non-scientific methods used throughout early history and up to today's modern techniques implemented and how they evolved. In addition the paper will discuss where the method of leak testing is heading based on the rapid advent in technology via computer based and automated equipment.

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Advances in The Inspection of Threaded Connections Using ACFMT

Presenting author(s): Mr Henry Sadek

Co-Authors: Dr Michael C Smith

Room: Pavilion 11 | 9:00 AM Wednesday, November 20, 2019

The downhole failure of a drillstring has huge cost implications for a project and fatigue damage to the threaded connections between the drillstring assemblies is a significant risk area. Due to this, the inspection of these connections at overhaul is a critical activity to ensure a reduced risk of failure. Conventional techniques for the detection of surface cracks, typically magnetic particle testing (MT) on magnetic materials or dye penetrant testing (PT) on non-magnetic materials, present challenges to the inspector, particularly when used on the box side of the connection. Problems with lighting and visibility to a box thread root creates variability in inspection performance, they require a high level of cleaning using chemical cleaners and do not provide auditable inspection data. Alternating Current Field Measurement Testing (ACFMT) provides a method to inspect threaded connections for surface cracking without the need for extensive pre-cleaning or controlled lighting. The technique does not require sight of the thread root and provides information of crack depth as well as surface length. All data is stored and available for later audit or further analysis. Recent advances in instrumentation and software have made the technique faster with improved sensitivity to small defects on non-ferritic threads. Trials are presented that indicate ACFMT offers improved inspection reliability and consistency between inspectors. This increased reliability could offer cost saving to the drilling industry through the reduction in downhole failures.

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Continuous Test Process for Railroads

Presenting author(s): Mr Albert Andrew White

Co-Authors:

Room: Pavilion 9 | 9:30 AM Wednesday, November 20, 2019

Ever since the inception of non-destructive rail inspection capabilities the process has been conducted by utilizing a slow speed operation often referred to as “stop/start” rail inspection. This type process is conducted utilizing a single qualified operator to collect the inspection data, analyze the inspection data, and immediately stop the inspection vehicle to verify any potential rail defect in real time. The consequence of one person performing each phase in real time requires the operation to be conducted at a relatively slow speed with limited production capabilities. In today’s railroad environment with increased traffic densities, it is becoming extremely difficult to obtain track time for the purpose of performing these rail inspections. As a result, Herzog Services Inc. recently developed a modified concept of the rail inspection process that can be performed at higher speeds commonly referred to as the “continuous test process”. The continuous rail inspection process relies on a non-stop inspection vehicle collecting the data at higher speeds in one phase, out sourcing the data to a remote location for review as the second phase, and delayed verification of the potential rail defect locations within a specified timeframe as the third phase. The continuous rail inspection process provides the railroad the option to perform the inspection as a three phased operation in lieu of this current process. Introduction of this process noticeably increases the inspection capabilities of the railroad, provides the opportunity to detect the potential defect before it reaches a critical size, and reduces potential rail failure. The long-term goal of the continuous test process is to improve the effectiveness and efficiency of rail inspection and related railway maintenance activities, while reducing disruption of commercial traffic.

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Changes in the ASME Boiler and Pressure Vessel Code with respect to Helium Mass Spectrometer Leak Testing

Presenting author(s): Mr Anthony J Heinz

Co-Authors: Mr David M Kuhn, Mr Paul Brad Shaw

Room: Pavilion 10 | 9:30 AM Wednesday, November 20, 2019

The 2017 and 2019 editions of the ASME Section V, Article 10, Leak Testing include a significant number of changes with respect to helium mass spectrometer leak testing. This presentation will review and discuss some of these changes, particularly the changes to Mandatory Appendix IX, HELIUM MASS SPECTROMETER – HOOD TECHNIQUE, and the Mandatory Appendix XI, HELIUM MASS SPECTROMETER – HELIUM FILLED CONTAINER-LEAKAGE RATE TEST, which is an entirely new Mandatory Appendix.

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Temperature Effects on Ultrasonic Readings

Presenting author(s): Mr Kenneth L Heaps

Co-Authors:

Room: Pavilion 11 | 9:30 AM Wednesday, November 20, 2019

This paper addresses temperature change effects on ultrasonic readings. It is well documented how material temperature effects ultrasonic readings, but it is not well documented how transducer temperature effects ultrasonic readings. Codes require temperatures of calibration blocks and components to be within 25 degrees F and research states that the thickness of steel, at elevated temperatures, increases about 1% every 100 degrees F. The focus of this paper is to quantify transducer temperature change effects on ultrasonic readings. The temperature change on the transducer, specifically the Lucite material, can have an even more drastic effect on the ultrasonic reading than the component temperature. This can be evidenced in an arctic environment by rolling the window down and placing a transducer with a Lucite delay tip outside and watching the delay line signal gradually get thinner and thinner. When a transducer is placed on a pipe that is above ambient temperature one should expect similar changes, but in the reverse direction. Can one also expect the longer the transducer is in contact with the pipe the more significant the change? When performing ultrasonic examination on pipelines on the North Slope of Alaska corrosion engineers cannot afford inconsistency in ultrasonic readings caused by temperature changes. This paper will attempt to quantify changes in ultrasonic readings over a wide diversity of ambient temperatures, elevated steel temperatures, transducer temperatures and associated transducer contact times.

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Ultrasonic Inspection of Carbon Steel Electric Flash Butt Welds in Rail and the Affect from Temperature on Acoustic Properties

Presenting author(s): Mr Gregory A Garcia

Co-Authors: Mr Brian Keith Wood, Mr Gregory Lehnhoff

Room: Pavilion 9 | 10:00 AM Wednesday, November 20, 2019

Electric flash butt welding (EFBW) of continuous welded rail (CWR) is one of the primary industry accepted methods for the joining of rail. The EFBW process uses a resistance heating and forging to join the entire area of the abutted rail end surfaces. For CWR to function efficiently and safely, it is imperative that EFBW joints have proper fusion between the two rails. In order to nondestructively verify the integrity of welds after manufacturing, the American Railway Engineering and Maintenance of Way Association (AREMA) Manual for Railway Engineering Chapter 4 Rail, recommends that magnetic particle inspection be performed. As the AREMA Manual is a recommended practice end users may also require that the manufacturer perform ultrasonic inspection (UT) in the fusion zone area in accordance with the American Society for Testing and Materials (ASTM) E-164 Standard Practice for Contact Ultrasonic Testing of Weldments. This may provide some guidance for inspection at ambient temperature, but it does not address the effect of temperature on the materials acoustic properties when the weld is inspected at temperatures other than ambient. Temperature affects the speed of sound and this effect has been known to vary with material composition. This paper discusses the affects from temperature on the acoustic properties of carbon steel rail electric flash butt welds and how it may affect the accuracy in measurement of flaw size and location.

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Leak Testing: Bulkhead Fittings

Presenting author(s): Mr Travis Dreyfoos

Co-Authors: Mr Kane M Mordaunt

Room: Pavilion 10 | 10:00 AM Wednesday, November 20, 2019

A new type of pressure bulkhead wire bundle seal fitting was implemented on Boeing’s 777X and 787 airplanes. The fitting is designed to protect, separate and seal wire bundles passing through the pressure bulkhead and can be disassembled much easier than past designs in case wire repairs are needed. Wires must pass through these bulkheads in continuous fashion to reduce connection/fail points and weight and must not leak such that cabin pressure and flight performance are adversely affected. Until now, the only method for leak testing the seal fittings was to pressurize the entire fuselage and listen or feel by hand for unacceptable leakage at the fitting locations. After years of effort to find a more practical solution, a prototype tool was finally developed to leak test the seal fittings prior to fuselage pressure testing at the point of installation. The first 777X to utilize the fittings and the new leak test tool passed the fuselage leak test with zero defects. The leak test tool can be used to pressure or vacuum (as appropriate) leak test virtually any type of bulkhead fitting with leakage performance requirements.

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Measuring Methods: Validating New NDT Techniques

Presenting author(s): Dr David Alleyne

Co-Authors:

Room: Pavilion 11 | 10:00 AM Wednesday, November 20, 2019

This talk is all about the measurement method and how we use a direct confirmation approach to test a new technology like the QSR1. The measurement theory of the QSR1 will be presented with the capabilities caused by the guided waves. The operation of a scanning depth gauge device designed to provide direct measurements for
comparison will be explained. Comparisons of the results from both devices will be used to validate the measurement from the QSR. This talk will highlight the approach of using different NDT techniques and how new technologies and ideas that incorporate advanced computational techniques and machine learning can be tested and validated using traditional and well understood measuring methods.

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Rolling Contact Damage Characterization in Rails Using Electromagnetic Field Imaging (EMFI)

Presenting author(s): Dr Anish Poudel

Co-Authors: Dr Matthew Witte

Room: Pavilion 9 | 10:30 AM Wednesday, November 20, 2019

Rolling contact damage (RCD) is an issue for railroads worldwide, especially heavy-haul railroads. Railroad owners grind the rail on a periodic basis for surface conditioning and to maintain rail profile. During grinding, profile measurement systems are used to provide an objective measure of the rail contour. Surface cracks are primarily evaluated based on visual inspection, and their evaluation is solely based on the expertise of trained railway personnel. This subjective process is not quantitative. Similarly, conventional non-destructive evaluation (NDE) technologies for the measurement of RCD cracks (e.g., dye penetrant inspection and magnetic particle inspection) are not practical for in-motion monitoring and are not capable of measuring key characteristics below the surface of the railhead. Methods are sought to automate and quantify rolling contact fatigue crack and pit depth measurement. This paper discusses the use of electromagnetic field imaging (EMFI) technology for rolling contact damage (RCD) characterization on railroad rails. A series of tests were conducted on rail samples with varying levels of RCD. An EMFI-based ECHO-3D flat sensor was fitted to a trolley that could scan the entire length of the rail. The orientation of the flat ECHO-3D sensor was manually adjusted at 4 mm (0.16-inch) increments to inspect the gage face, the gage corner, and the running surface of the test rails. The scanning resolution used for this proof-of-concept study was 1 mm (0.04-inch) at 1.6 km/h (1 mph). A lift-off study also was conducted to understand the effect of an air gap on detection and characterization performance. Finally, destructive tests were performed to determine actual RCD depth at a point in the test rails. It was observed that the RCD crack depths all appear to be around 2 mm (0.08 inch) which were consistent with the ECHO-3D severity measurements.

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Estimating and Improving on the Probability of Detection for Fine leaks on Semiconductor Gas Lines

Presenting author(s): Mr Benjamin Brown

Co-Authors: Mr Jimmy D Love

Room: Pavilion 10 | 10:30 AM Wednesday, November 20, 2019

Delays in construction can impact the startup of the production process in a leading-edge semiconductor plant. This delay can cost facilities owners millions of dollars. Semiconductor process gas lines are installed quickly under immense schedule pressure and are expected to reliably deliver ultra-high purity gas to production equipment in the factory.

Helium mass spectrometer leak detectors are used to qualify gas lines in these factories. The helium leak rate specification for each weld and each mechanical connection in these gas lines is less than 1 x 10^-9 std. cc/sec. Site conditions and schedule pressure unique to our industry dictates that this leak rate specification must be achieved without the system level calibration described in ASME and ASTM standards for tracer probe gas leak testing.

This paper uses test data from a two (2) year period to estimate the probability of detection for leaks ranging in size from 1x10^-5 to 1 x 10^-7 std cc sec in semiconductor gas piping systems using industry standard equipment and techniques. The paper also describes the means and methods deployed by site personnel at two facilities to increase the probability of detection over the last year.  The results of this study point to possible changes in industry specifications to make the leak testing of gas lines more reliable.

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Detection of CUI on Piping, Vessels and Sphere Legs

Presenting author(s): Mr Ankit Vajpayee »

Co-Authors: Mr David E Russell

Room: Pavilion 11 | 10:30 AM Wednesday, November 20, 2019

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Flash Infrared Thermography FEA Analysis for Rail Base Defect Detection

Presenting author(s): Mr Connor Chase Seavers

Co-Authors:

Room: Pavilion 9 | 1:00 PM Wednesday, November 20, 2019

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 discusses the use of transient thermal finite element analysis (FEA) to simulate and explore the capabilities of flash infrared thermography (IRT) for the detection of common rail base defects. Results from this study revealed that thermal contrasts approximately 2°C can be achieved in defective areas depending on the geometry and location of the defect present. A theoretical study also was performed to help validate a simulation model, showing approximately a 0.5°C difference in surface temperature values found from simulation and theory. Finally, to better understand rail base defect detection capabilities using flash IRT, the resulting simulation data also was compared to specifications of the commercially available infrared cameras. Findings from these demonstrate the feasibility of applying IRT approach for the rail base defect detection and characterization.

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Nine (9) Design Features that make Hazardous Material Package Closures Easier to Leak Test.

Presenting author(s): Mr Paul Brad Shaw

Co-Authors:

Room: Pavilion 10 | 1:00 PM Wednesday, November 20, 2019

Some hazardous material package closures are relatively easy to leak test reliably and quickly. Other designs can be very difficult to leak test. This paper will identify nine (9) design features that can make package closures relatively easy to reliably test to high leakage rate sensitivities, and consistent production schedules. Neglect of one or more of these features can result in a closure design that is difficult to reliably leak test to a high sensitivity.

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Developments in High-Temperature, Online Ultrasonic Integrity and Corrosion Monitoring

Presenting author(s): Dr Tim Stevenson

Co-Authors:

Room: Pavilion 11 | 1:00 PM Wednesday, November 20, 2019

In the oil and gas and power generation sectors, it is predicted that 25% of the costs involved in outages could be avoided by replacing conventional risk-based inspection strategies during periodic planned shutdowns, with in-service inspection and monitoring. Online, non-intrusive, ultrasonic corrosion monitoring and asset integrity transducers are becoming increasingly popular to enable both maintenance and operations teams to enhance process unit productivity, reduce shutdowns and manage maintenance whilst enhancing safety. Presented here is a review of the current and emerging technologies for ultrasonic inspection and monitoring to detect, track and assess corrosion in high-temperature (up to 550 °C / 1022 °F) assets. From the development and challenges with the selection of piezoelectric elements, transducer design, and coupling, to the availability and application of commercial systems in the field. Selecting what data to collect, who will benefit from it, how it will be stored, and the value of increased frequency of collection to data quality will be explained. Their use within the constraints of NDT regulations and standards, including calibration and temperature compensation, will also be covered. The location and environment of UT data collection are considered, including hazardous and potentially explosive environments, working at height /rope access and the integrity of insulation or cladding. Finally, a case study, highlighting a field example using the HotSense platform is presented for monitoring corrosion and explores the key factors which must be considered when selecting an in-service ultrasonic system. Whilst the focus is on oil and gas, the development of these extreme environment resilient platforms also lend themselves to be developed to asses other damage mechanisms, such as weld defects, operational issues (gas void detection) and material flaws in a range of other sectors including nuclear and fossil fuel energy generation, and process control.

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Automated Phased Array Inspection of Rail Wheels

Presenting author(s): Mr Paul Grosser

Co-Authors:

Room: Pavilion 9 | 1:30 PM Wednesday, November 20, 2019

This paper covers the design, system automation, calibration, and validation of an automated ultrasonic system for the inspection of new and in-service wheelset assemblies from diesel-electric locomotives and gondola cars.  The system uses Phased Array (PA) transducers for flaw detection and Electro-Magnetic Acoustic Transducers (EMAT) transducers for the measurement of residual stresses.  The system collects, analyzes, evaluates and categorizes the wheelsets automatically.  The collected data is archived for future comparison and trending.  It is also available for export to a portal lathe for increased efficiency and accuracy of machining, therefore allowing prolonged wheel life.

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Leak Testing: Composite Layup Bagging

Presenting author(s): Mr Travis Dreyfoos

Co-Authors: Mr Kane M Mordaunt

Room: Pavilion 10 | 1:30 PM Wednesday, November 20, 2019

Boeing Research & Technology created and implemented a new processes for leak testing large composite layup bags prior to autoclave curing using low pressure helium injected under the bag wherein only the weight of the bag is used to create pressure differential across leak paths. To produce large bags that satisfy allowable leak down rates which ensure acceptable compaction and cure properties such as those used to layup composite rocket fuel tanks, airplane wing skins and other large parts is often a challenge that can delay curing hours or even days in some cases. A high sensitivity helium sniffing leak detector equipped with custom probe attachments is used to inspect the composite bags. In one test case, bagging was installed on the inside and outside diameter of a large cylindrical cryogenic fuel tank measuring 20ft in diameter by 60ft long for the Boeing Space Plane program. The inspection was done quickly and effectively resulting in improvement from a failing leak rate to about 2.25 inches Hg loss over 5 min which the team agreed was extraordinary considering the large square footage of the bags. To our knowledge this is the first use of helium leak detection in a composite bagging application at Boeing done in this manner.

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Enhanced Performance of Magnetic Flux Leakage Inspection of Storage Tanks

Presenting author(s): Mr Neil Pearson

Co-Authors:

Room: Pavilion 11 | 1:30 PM Wednesday, November 20, 2019

Magnetic Flux Leakage (MFL) technology is a robust and cost-effective approach for the inspection of storage tank floors. The primary advantage of the MFL approach is its ability to locate and estimate the geometries of discontinuities over large areas in a quick and efficient manner. While characteristics of MFL signals have been reported to correlate to the volumetric loss of defects, these observations have normally related to defects with similar profiles that grow proportionally. However, defects with different profiles can have corresponding MFL signals with similar amplitudes creating ambiguity. In this paper, a collection of complementary sensors and visual analysis tools are presented that can assist the inspector to formulate a repair strategy through the classification of defects. For example, one route to improved sizing accuracy is to first determine whether a defect comes from the top-side or bottom-side of a steel floor. The patented STARS approach developed by Eddyfi Technologies is a solid state sensing system that can measure top-side defects, which not only helps with identifying the source of corrosion but also improves the accuracy of defect size estimation from MFL signals by utilising appropriate top-side/bottom-side calibration profiles. This paper describes advanced high-resolution MFL, the impact of MFL bandwidth limitations, STARS technology and defect classification to achieve consistent and reliable inspections of storage tank floors.

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Evaluation of Wheel Impact Load Detector on Curved Track

Presenting author(s): Dr Anish Poudel

Co-Authors: Dr Matthew Witte

Room: Pavilion 9 | 2:00 PM Wednesday, November 20, 2019

Conventional wheel impact load detector (WILD) systems are usually installed on a tangent track. Results obtained from these systems are used to effect wheel removals to reduce infrastructure damage and broken wheel derailments. However, many broken wheels fail in service absent of high impacts as measured by the conventional WILD. Many wheels that fail exhibit signs of fatigue damage at or near the edge of the tread on the field side of the wheel and are not reliably captured by the conventional WILD systems. A new concept called WILD Cracked Rim Detector (WILDCARD) was developed by assembling commercially available WILD components on curved track in conjunction with tangent WILD with the purpose of detecting wheels with damage outboard of the tapeline. Transportation Technology Center, Inc. (TTCI) performed an investigative NUCARS®* analysis to predict wheel lateral position and testing to verify the result on wheel impact level. The experimental tests included three commercial WILD systems. Twin systems from each vendor were placed on the curved and tangent track for comparison of measurements obtained under both operating conditions. Testing was performed at Sections 33 and 31 on the High Tonnage Loop (HTL) at the Facility for Accelerated Service Testing (FAST) at the Transportation Technology Center (TTC) near Pueblo, CO. Results obtained from this work demonstrated the trains traveling on curved track between 30 mph and 40 mph show potential for recording impact forces similar to tangent WILD. Also, it was observed that the range of dynamic force in a defective wheel detected by the WILDCARD system was higher than in the tangent WILD systems. Train operating conditions do affect results.

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Mass Spectrometric Helium Leak Detection in Large Vacuum Vessels: Prediction of the sensitivity and response time by a Finite Element Method

Presenting author(s): Dr Venkat N Ramani

Co-Authors:

Room: Pavilion 10 | 2:00 PM Wednesday, November 20, 2019

Helium Leak Testing Method is a vital Non-Destructive Testing Technique in Vacuum as well as Pressure vessels designed for Petrochemical, Pharmaceutical, Chemical, Aerospace and Nuclear Applications. The extensive range of application, detection of precise location of leak and its capability to be applied in on-line or off-line conditions, have made this technique very relevant in wide-ranging situations. A global model exists to estimate the response time and sensitivity of Helium leak detection. This model involves a mathematical expression involving volume of the test system, Speed of evacuation, and takes into account the configuration of Leak detection in the pumping system. The expression of the global model is independent of geometry of the vacuum vessel, pressure and the locations of leak with respect to the Leak Detector. Most often, it has been found that the practically observed values of sensitivity and response time are quite different from the theoretically predicted values. It is attempted in this work to predict the two factors - response time and sensitivity, by a numerical approach. In this approach, the helium flow path is divided into finite elements, the collision of helium molecules with the background air molecules and at the wall are considered. The results show that the detection sensitivity and response time are dependent on pressure and location of leakage in the system.

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Detecting H2S Damage in Cement Lined and Unlined Ductile Iron and Steel Force Mains

Presenting author(s): Mr Ankit Vajpayee »

Co-Authors: Mr David E Russell

Room: Pavilion 11 | 2:00 PM Wednesday, November 20, 2019

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Nondestructive Testing and Risk-Based Qualification of Railroad Tank Cars

Presenting author(s): Mr James R Dinell

Co-Authors: Mr Michael A Tait

Room: Pavilion 9 | 2:30 PM Wednesday, November 20, 2019

This session will outline the current programs and requirements using NDT in the United States rail industry. The presentation will focus on maintenance and US federal regulations of railcars paying particular detail to railroad tank cars. The presentation will include NDT methods, US Federal Regulations, and requirements for NDT in maintenance of ageing railroad tank cars. This includes periodic structural integrity inspection requirements, typical in-service defects found in railcars and rail components. The United States Department of Transportation allows the use of several NDT methods (e.g. UT, MT, PT, RT, AE, or VT) for the inspection of in-service railroad tank cars. The inspections help evaluate high stress areas, including welds, on the tank and tank attachments. The results are used to qualify tank cars and establish a risk-based inspection cycle. This presentation will address the advantages and limitations of each NDT method as it relates to a risk-based railroad tank car inspection program.

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Leak Testing: Open Wing Structure

Presenting author(s): Mr Kane M Mordaunt

Co-Authors: Mr Travis Dreyfoos, Mr Dennis Mereness

Room: Pavilion 10 | 2:30 PM Wednesday, November 20, 2019

How does one pressure leak test an airplane wing fuel tank that is missing one side of the structure? Boeing Research & Technology and 777X Manufacturing developed and optimized a bagging process for plugging open fuel tank structure prior to pressure testing. The process uses two sheets of composite bagging film over the open part of the tank - the inner film being relatively thin thereby allowing ease of handling and the outer film being heavier for reinforcement. To hold the bags onto the wing structure while under pressure, vacuum chambers are installed all the way around on the wing surfaces to apply holding force and also to remove helium that may leak past seals and contaminate the leak test. Using this process, Manufacturing was able to reach 0.5 psig fuel tank pressure as required. The bag was proof tested to 1 psig before rupturing, containing over 12,000 lbs. of force. The method is affordable, flexible, portable, and helpful for emergent issues.

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A Solution for Corrosion Profile Measurements using Guided Waves

Presenting author(s): Dr David Alleyne

Co-Authors:

Room: Pavilion 11 | 2:30 PM Wednesday, November 20, 2019

The corrosion that develops over time within structures and pipelines is one of the most pressing integrity problem today. In many instances the corrosion is hidden or inaccessible due to attachments, welds or supports. Corrosion under insulation and at pipe supports (CUI and CUPS) are two examples of damage mechanisms that are of interest to the industry. Therefore, a large proportion of aging assets and pipelines have hidden inaccessible positions with significant risk of corrosion. The commercial advantages of using guided wave inspection methods that are able to cover 100% of the volume of many metres has led to this methodology being attractive to the NDT industry and its use has grown over the last 20 years. The operation of the measurement method of a short range scanning device will be explained and demonstrated. This device can be used to measure wall thickness and remain thickness remotely, without direct access to the position measured. A number of results from performance testing and trials at different geographic global sites (industrial and laboratory) will be used to elucidate capability and application.

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Aircraft Structures NDT with ET Arrays

Presenting author(s): Dr Neil J Goldfine

Co-Authors: Dr Andrew P Washabaugh, Mr Todd Dunford, Mr Karen Walrath, Mr Mark Windoloski, Mr Stuart Chaplan, Ms Karen Diaz

Room: Pavilion 9 | 3:30 PM Wednesday, November 20, 2019

This paper reviews new developments in aircraft structures NDT using flexible eddy current arrays (such as the MWM-Array by JENTEK). There are three common types of eddy current arrays (1) compilations of single eddy current testing (ET) coils that are essentially used independently in a parallel or multiplexed operation and are mounted in a shuttle that is rigid and shaped similar to the surface being inspected to enable imaging; (2) arrays of flat spiral coils or multiple layered coils that act as both drive and sense elements and are multiplexed, typically in groups of four or eight at a time avoiding excitation of neighboring coils to avoid cross talk; and (3) fully parallel arrays that incorporate a single drive with longer linear segments, such as the MWM-Array, typically with single rectangle or dual rectangle drive constructs, that enable simultaneous measurement for all channels with essentially no cross talk between channels. This paper describes applications of the third type of array to (1) corrosion imaging in multiple layered aircraft joints, (2) surface and buried crack detection, and (3) bolt hole inspection, including cracks at edges. This paper also describes the use of model-based multivariate inverse methods (MIMs) for rapid data analysis. Also described are the advantages of using a combination of simultaneous measurement of impedance for multiple frequencies at all sensing elements along with these MIMs to enable automatic correction for uncontrolled conditions such as defect position within the array, varying structure layer thicknesses, and liftoff (from varied paint thickness or surface condition).

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The Advantages, and the Hazards of New Helium Mass Spectrometer Leak Detectors

Presenting author(s): Mr David M Kuhn

Co-Authors:

Room: Pavilion 10 | 3:30 PM Wednesday, November 20, 2019

Many of the currently marketed helium mass spectrometer leak detectors are variations of the “Multi-Mode” design. While the multi-mode designs offer many wonderful capabilities, many, and perhaps all of these multi-mode instruments have shortcomings that are not immediately obvious. This presentation will explain what a multi-mode helium mass spectrometer design is, and specific vulnerabilities of this design that can generate significant delay and expense for users who are not familiar with the vulnerabilities the multi-mode design. This presentation will also discuss ASME code implications, and procedural cautions that can mitigate the vulnerability of the multi-mode while making use of the advantages of these instruments.

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Ultrasonics in Automobile Industry - Measuring or Testing?

Presenting author(s): Mr Andrey Bulavinov

Co-Authors: Mr Roman Pinchuk, Mr Andrey Samokrutov

Room: Pavilion 11 | 3:30 PM Wednesday, November 20, 2019

Ultrasonics is one of the most applied techniques for quality assurance in the automobile industry. Although, the technical application rules here differ from those in other fields of industry. Primarily they are driven by enormous high throughput requirements and high integration level of inspection machines into production lines. In the current contribution, the most typical “facial features” of ultrasonic testing in car production are exemplified by practical application cases, e.g for testing and measuring of motor and gearbox parts (pistons, liners, input shafts). Advantages and limitations of regular UT approaches are discussed in a pragmatic and nonfiction way.

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Fracture Toughness of Ferromagnetic Metal Assessment by NDT Method Measuring Steel Magnetic Property - Coercivity

Presenting author(s): Mr Roman Solomakha

Co-Authors: Dr Gennadiy Bezliudko, Ms Svitlana Savluk

Room: Pavilion 9 | 4:00 PM Wednesday, November 20, 2019

Safety and economic reasons in combination with aging pipeline infrastructure generated a foremost task to find out the feasibility and methodology of reliable quantitative non-destructive assessment of steel state. One of the most promising approaches is to base the assessment on material fracture toughness (FT). For practical application of this approach obtaining material fracture toughness via NDT method is indispensable. Transformations in pipe steel structure resulting in FT changes are caused by a combination of many factors. The method based on measurements of magnetic coercivity is highly sensitive to structural changes caused by heat treatment (during welding) and mechanical influence (during lifetime) and demonstrates favorable correlation to FT in bench testing of pipe steel S335 family. Two sets of samples were tested: For modeling FT changes stipulated by heat treatment: as-rolled, annealed, as-quenched for max hardness, as-quenched with tempering samples were used. For modeling FT changes stipulated by mechanical influence: as-rolled samples and samples after considerable mechanical loadings (corresponding to the material after yield point and close to the fracture) were used. Change of the samples’ FT from max to min goes along with the increase of magnetic coercivity 3-4 times. Choice of magnetic coercivity among other NDT methods enables to do the inspection quickly, on operating pipelines, with simultaneous obtaining coercimetrical assessment of metal fatigue.

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Leak Testing: Wire Bundles

Presenting author(s): Mr Travis Dreyfoos

Co-Authors: Mr Kane M Mordaunt

Room: Pavilion 10 | 4:00 PM Wednesday, November 20, 2019

Many aircraft wires carry power or signals from the pressurized cabin and cockpit to unpressurized areas in the wings, wheel wells and tail. As such, these wires, which pass continuously through pressure bulkheads, are bundled and sealed to contain fuselage cabin pressure during flight. Boeing’s 777X and 787 programs use a relatively new process to seal wire bundles passing through bulkheads. Wire bundles are typically built at remote supplier wire shops and delivered to Final Assembly Systems Installation shops where they are installed on the airplane. The remote location of suppliers relative to installation makes it difficult to obtain quality feedback for the electricians building these bundles. A new tool was developed which enables wire shop electricians to leak test bundles immediately after building them. The tool works by sealing a clamshell type leak test chamber around a wire bundle and applying relatively low pressure of about 1 psig to the seal side of the bundle. Bubble leak test solution is then applied to the low pressure side so the electrician can validate the seal integrity and deliver first time quality to the downstream customer. The first 777 Flight Test airplane to use this leak test tool resulted in zero leak defects.

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Guidelines for Comparative Evaluation of Thermography Systems for NDT

Presenting author(s): Dr Steven M Shepard

Co-Authors: Dr James R Lhota

Room: Pavilion 11 | 4:00 PM Wednesday, November 20, 2019

The increasing popularity of Thermography for NDT (TNDT) has given rise to numerous alternatives for cameras, excitation sources and processing methods, spanning a large range capability, cost and system footprint. A new or prospective entrant to the field faced with these choices is likely to turn to the TNDT equipment manufacturers, social media (LinkedIn, Youtube etc.), trade publications or academic journals for guidance. However, such sources are not necessarily objective or without bias in their assessments, and the newcomer may find the terminology, techniques and underlying math and physics confusing, compared to the more familiar NDT disciplines (e.g. UT, RT). For example, modern TNDT relies increasingly on signal processing to extend range and sensitivity, perform quantitative measurement and enable automation. The most widely used methods, Thermographic Signal Reconstruction (TSR), Pulse Phase (PP), Lock-In (LI) and Principal Component Analysis (PCA) have all been demonstrated to outperform unprocessed results. However, the methods are quite different in their underlying mathematical approaches and in how results are presented to, and must be interpreted by, the end-user. In the past few years, numerous studies have attempted to provide comparative analysis of some, or all of these techniques. In this paper, we will evaluate several recent studies and compare their specific objectives, evaluation criteria, procedure, results, an analysis and conclusions, and identify strengths and pitfalls specific to thermography that should be considered in future comparative studies.

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Advances in Pulsed Eddy Currents Solutions for Inspection of Steel Under Corrosion Scabs

Presenting author(s): Ms Andreanne Potvin

Co-Authors: Dr Vincent Demers-Carpentier, Dr Maxime Rochette, Mr Sebastien Champagne, Mr David Deschatelets, Mr Marco Michele Sisto

Room: Pavilion 9 | 4:30 PM Wednesday, November 20, 2019

Atmospheric corrosion of low-carbon steel structures may result in corrosion product build-up on the steel surface. This build-up, or corrosion scab, may be several millimeters thick and prevents the use of many non-destructive techniques for the estimation of the remaining steel wall thickness. Typically, surface preparation and scab removal are not recommended due to safety considerations and risk of pipe leakage, forbidding the application of conventional ultrasonic and visual inspections techniques. Radiographic methods are commonly used for scab inspections, but typically require access from both sides of the inspected object, limiting their applicability to pipes or relatively small structures. Also, it can be a challenge to find the deepest area of wall loss while analysing the cross-section image of severe and irregular corrosion surrounded by scab material. These limitations are overcome by the Pulsed Eddy Currents (PEC) inspection technology, which is now being recognized as an effective tool for the estimation of wall loss under scabs on low-carbon steel structures. PEC can be applied to large and small structures, both insulated and non insulated, including pipes of any diameter (above 1 inch OD), vessels, tanks, fireproofed sphere legs, etc. Also, it requires no surface preparation, limiting the safety and leakage risks associated to scab removal. However, PEC inspection on thick scabs is nontrivial because large build-ups of corrosion material may distort the PEC signal, affecting the accuracy of wall loss estimation. In this communication, we analyze the effect of corrosion material on the PEC signals and propose several mitigation techniques. We present novel analysis tools that help the inspector to evaluate the quality of the PEC signal to gain confidence in the wall loss estimation. A novel PEC array probe for inspection of scabs with high spatial resolution is also presented, and we report inspection results on ex service and manufactured pipe samples, providing experimental evidence of the effectiveness of these state-of-the-art PEC corrosion scab inspection tools.

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The Calibrated Leak Method of Pressure Change Leakage Rate Testing

Presenting author(s): Dr William Harris

Co-Authors: Mr Paul Brad Shaw

Room: Pavilion 10 | 4:30 PM Wednesday, November 20, 2019

Although rarely described in training literature, the “Calibrated Leak Method” of Pressure Change Leakage Rate Testing can be a highly useful tool. The Calibrated Leak Method permits the use of greatly simplified math, with significantly improved test confidence as compared to other “high” sensitivity pressure change leakage rate measurement techniques. This paper will review the Calibrated Leak Method of pressure change leakage rate measurement, the advantages of the method, and recent examples where this technique has demonstrated significant advantages.

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Benefits of 3D Visualization for High Resolution Video Measurement

Presenting author(s): Mr Charles Janecka

Co-Authors:

Room: Pavilion 11 | 4:30 PM Wednesday, November 20, 2019

Accuracy and precision are the two most important aspects of any type of measurement, and great advances have been made to improve these. In the field of visual measurement, however, picking the right measurement point is just as important. Advances in the field of remote visual inspection have been made in lensing, illumination, and imaging, such that the resulting measurements are more precise than ever. This precision, though, is only as good as the point picked. Modern videoscopes are only able to take measurements based on the points provided to them by the inspector, making the inspector, in a way, a part of the measurement system itself. 3D modelling helps make this process easier and more efficient. Picking the correct point is helpful, if not crucial, as there are certain applications where picking the appropriate point can have dramatic results. One such case is in measuring the edge of a surface. If not done properly, the point can “fall of the edge,” leading to inaccurate results. 3D modelling also allows inspectors to evaluate the surface of what is being measured. This is still a qualitative analysis, but it leads one to be more confident that the correct point is being used. One example of this is weld inspection, where issues such as undercut can more quickly be evaluated. It also allows the user to quickly pinpoint an area of interest to measure, which can dramatically speed up the inspection time and produce a more reliable, robust system.

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The Preliminary Research on the Array Probe with Bobbin Transmit and Pancake Receive for Inspection of Heat Transfer Tube

Presenting author(s): Mr Pan Qi

Co-Authors:

Room: Pavilion 9 | 5:00 PM Wednesday, November 20, 2019

Heat transfer tube as border between the first and second loop of nuclear island in nuclear power plant (NPP), plays a very important barrier role. If the tubes ruptured, it will lead to nuclear leakage, which will be a major safety accident. Therefore, the quality of tubes has been focused on, both at the stage of pre-service and in-service. At present, nickel-based alloy is conventional material for the tube and eddy current testing is the most important technical guarantee for its quality. However, different probes are used in the different ranges, bobbin is suitable for qualitative and quantitative inspection of full-length tube and array probe is for qualitative test for special position such as tube expanding transition section. In this article, a new array probe with bobbin coil transmit and pancake coil receive is presented.For this probe, the mode of bobbin coil transmit and pancake coil receive is just for longitudinal defects and pitting (hole) testing and pancake coil transmit and pancake coil receive is just for circumferential defects testing. This paper focuses on study of the characteristic changes of signals for specific defects under the former detection mode by FEM simulation.Firstly, the influence of coils spacing variation on signal amplitude under fixed frequency is studied. The is set to 50KHz, the change of amplitude of pancake coil is observed when the coils spacing varies from 2mm to 12mm. Secondly, the influence of frequency variation on signal amplitude under fixed coil spacing is studied. The coils spacing is set to 2mm, the change of amplitude of pancake coil is observed when the frequency varies from 50KHz to 800KHz. The results show that the coils spacing should be the closer the better firstly and the best testing frequency need to be determined for the different testing tube..

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Leak Testing: Single Fittings

Presenting author(s): Mr Kane M Mordaunt

Co-Authors: Mr Travis Dreyfoos, Mr Andrew Newton

Room: Pavilion 10 | 5:00 PM Wednesday, November 20, 2019

A highly accurate differential pressure change leak test has been developed and tested for leak checking individual pipe/tube fittings without pressurizing the tube system, such as in a hydraulic fluid system. The unique aspect of this method is the development of a clamshell fitting and internal structure that quickly encapsulates the test fitting of interest to a leak tight state so that it can then hold pressure/vacuum for a long period of time while leakage is detected by comparing against a "zero leak" reference volume using a capacitance differential manometer. Most pressure change leak tests are capable of achieving accuracies of 1.0E-02 atm cc/sec at best and require long test times and temperature and pressure compensation to achieve that accuracy. The new apparatus can provide theoretical accuracies in the E-06 atm cc/sec range independent of environmental factors. Testing has confirmed accuracy of E-04 atm cc/sec in reasonable test times of less than 1 hour. Further work is underway to achieve E-06 atm cc/sec accuracy.

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In-Situ Thermo-Acoustic Characterization of Shear Banding and Fracture in a Metallic Glass

Presenting author(s): Mr Amlan Das

Co-Authors: Mr Phillip Kagebein, Mr Alex Prather, Mr Stefan Kuechemann, Mr Robert Maass

Room: Pavilion 11 | 5:00 PM Wednesday, November 20, 2019

Inhomogeneous serrated plastic flow and subsequent fracture in a metallic glass all produce acoustic emission pulses. In this work, we use in-situ pyrometry and in-situ acoustic emission to probe plastic flow and fracture in Zr-based metallic glass. Fracture is accompanied by temperature spikes of approximately 600°C within less than 100 µs. The measured heating profiles with rates of up to 1e7 K/s allow us to determine the dynamical glass transition temperature. A continuous wavelet analysis of the acoustic emission pulse from fracture reveals an intermittent crack propagation, with phases of activity lasting 5-15 µs. Our findings show the final stage of a shear-band-to-crack transition in terms of time scales and temperature excursions, the latter of which remains below the melting temperature of the material. In serrated flow, temperature excursions within the sample remain below the detection threshold of 300°C. However, acoustic emission pulses emitted from shear banding during plastic flow show strain dependent frequency response. We associate the different AE pulse frequency bands with different internal processes like shear-banding and cavitation occurring during deformation of the metallic glass, which allows us to pinpoint the moment when a shear band transitions to a crack and preempt the onset of failure.

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Study on Multi-Frequency Phased Array Ultrasonic Technique

Presenting author(s): Dr Byung-Sik Yoon

Co-Authors:

Room: Pavilion 9 | 9:00 AM Thursday, November 21, 2019

Phased array ultrasonic testing (PAUT) is increasingly utilized in the power generation and nuclear power industries thanks to its ability to steer and focus an ultrasonic beam. Moreover, PAUT can scan electronically to minimize scan complexity and increase inspection speeds. PAUT is also the basis for very innovative data processing techniques such as full matrix capture (FMC) and total focusing method (TFM). The selection of a probe is mainly determined by the target material and objectives of inspection. To inspect homogenous and low attenuation materials, 5 MHz or higher can be used. However, for materials such as stainless steel or austenitic material, the frequency must drop to 1.5-5 MHz. In the case of thick parts, or cast austenitic stainless steel (CASS), even lower inspection frequencies in the range of 0.5-1 MHz are required. The possibility of using multi-frequency probes offers new opportunities to improve the versatile character of PAUT. That is making it more universal by having a single probe that can cover both frequency ranges. This paper presents the evaluation results of multi-frequency probes that are currently available and experimental results using a dual frequency phased array probe.

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Advancements in NDE Technology for HRSG Combined Cycle Power Plants

Presenting author(s): Mr Terry J Haigler, Jr

Co-Authors:

Room: Pavilion 10 | 9:00 AM Thursday, November 21, 2019

Avoiding failures at Heat Recovery Steam Generator (HRSG) power plants is a major priority for owners and operators. Component or system failures can be extremely expensive, force unplanned outages and quickly lead to a safety hazard for employees and even death. A major role in the prevention and maintenance of power plant assets is Nondestructive Testing (NDT). Technology development has been advancing with a continuous flow of new techniques entering the market. With today's seemingly endless options for NDT, it’s a challenge for owners and operators to effectively evaluate their options and select the best method and technique for their specific inspection needs. Intertek AIM will present an overview of the HRSG design including components and materials routinely inspected using NDT. When choosing an NDT technique, it’s imperative to understand the defect characteristics that will negatively impact your plant systems. Detailed descriptions and examples will be given on potential failure mechanisms associated with HRSG components. Building on potential failure’s Intertek AIM will provide detailed discussions on new NDT technologies including phased array, pulsed eddy current, EMAT, drones, eddy current array, borescope, ping testing, resonant testing and microwave. Applications for each method will be provided along with advantages and limitations. A post-inspection summary will be given detailing the latest in metallurgical and engineering solutions to determine the root-cause of defects. Engineering solutions such as data analytics and machine learning will be discussed as future engineering solutions for large data sets and analysis.

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The Fourth Revolution of Nondestructive Testing: Interconnection, Feedback, Digitization, IoT, and Integration into Smart Factory

Presenting author(s): Dr Johannes L Vrana

Co-Authors:

Room: Pavilion 11 | 9:00 AM Thursday, November 21, 2019

Historians split the industrial revolution into three phases: mechanization (steam engine), technical (electronics, mass production) and digital (microelectronics) revolution. A similar development occurred in nondestructive testing: tools, like lenses or stethoscopes allowed to enhance human senses, the conversion of waves makes the non-visible visible and offers a view into the components, and finally digitization, automation and reconstruction. During the overall industrial development NDT was one of the key players guaranteeing the quality and success of the produced goods. In the meantime, a fourth industrial revolution occurs: informatization, digitization and interconnection of industrial production, information transparency, technical assistance, and decentralized decisions. Like before NDT will be essential for the success of this fourth revolution, since NDT offers the data which is necessary for a successful smart factory. For NDT this means a radical change. An interconnected production environment must have unhindered access to the results of the inspections so that they can be used for feedback loops and other statistical evaluations. Inspectability needs to be considered during design and the reliability of the evaluation of the inspection will play an increasingly important role. This publication shows concepts how NDT can be integrated into Industry 4.0 landscapes. The reference architecture model industry 4.0 (RAMI 4.0) allows an identification of the digital component. The Industry 4.0 asset administration shell is the interface between the industry 4.0 communication and the physical device. OPC-UA becomes the standard communication protocol for industry 4.0. DICONDE is a communication and data format for inspection and meta data. AutomationML is a data format for plant layout. Finally the industrial data space initiative guarantees data sovereignty.

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Air-coupled Ultrasonic Phased Array – Noncontact Electronic Scanning with a 16 Element Linear Array

Presenting author(s): Mr Tobias Gautzsch

Co-Authors: Mr Andreas Mueck, Mr Andreas Bodi, Mr Manuel Lucas, Mr Werner Krause, Mr Mario Kiel

Room: Pavilion 9 | 9:30 AM Thursday, November 21, 2019

Air-Coupled ultrasonic testing (ACUT) is a well-known non-destructive testing method which is commonly used especially for the detection of delamination and impact damage in ceramics, honeycomb structures and other composite materials. The technology typically uses a mechanical scanning mechanism to create a C-scan image in which one pixel represents the ultrasonic signal of one single measurement point. This leads to long scanning times or coarse spatial resolution depending on the demands of the testing results. Recently, ultrasonic phased-array technology was applied in ACUT in terms of annular arrays to achieve an electronically adjusted focal depth [1] or to utilize multiple frequencies at the same time to increase bandwidth and post-processing potential [2]. Both approaches utilize three or four circular elements and have a focal spot on the acoustic axis of the transducer. In this paper, a newly designed transducer will be presented that features 16 rectangular elements with a pitch of 2 mm and a mean frequency of 400 kHz. Laboratory measurements of relevant test objects will be shown to demonstrate the possibility to excite each element individually and to create a virtual aperture by applying focal laws. By using the correct delay laws, the focal spot with a diameter of ~3 mm can be shifted along the transducer axis. This enables electronic linear scanning, transferring the technology from conventional liquid coupled phased array to non-contact air-coupled ultrasonic testing. [1] Mück et al., “Phased array probes for non-contact ultrasonic testing”, ECNDT Gothenburg 2019 [2] Gautzsch et al., “A new approach to air-coupled broadband measurement Effective testing of composite laminates by using a new multi-element transducer”, NDT in Canada 2018, Halifax

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Robotic Inspection of In-Service Storage Tanks using Pulsed Eddy Current Array Technology

Presenting author(s): Mr Jerome Vaganay

Co-Authors: Mr William O'Halloran, Mr Eric Levitt, Mr Matthew Crist, Mr Clint Collins, Dr Vincent Demers-Carpentier, Dr Maxime Rochette, Mr Marco Michele Sisto, Ms Andreanne Potvin

Room: Pavilion 10 | 9:30 AM Thursday, November 21, 2019

Pulsed Eddy Current (PEC) has been successfully deployed over the last decades for a variety of corrosion-related applications. The technology has proven to be an efficient screening tool for detection of corrosion in low alloy carbon steel. Recently, multi-element sensors using Pulsed Eddy Current Array (PECA™) technology were deployed in the field. The improved productivity and resolution possible with this new technology opened doors to innovative applications such as the inspection of storage tank floors while the asset is in-service. Eddyfi’s PECA™ system is fully integrated in a battery-powered autonomous robot designed and manufactured by Square Robot for in-service inspection of aboveground storage tanks. The SR-1 robot, certified for Class 1 Division 2 hazardous locations, is routinely operated by Veritank in tanks filled with petroleum middle distillates. The robot is launched through the roof manhole, lands on the tank’s floor, and autonomously rolls in contact with the floor while collecting PEC averaged wall thickness data. The PEC data as well as status information is sent in real time to the operator located in a control van near the tank over a thin fiber optic tether. This paper presents typical deployment of the solution, results obtained with the robot in diesel tanks, challenges and benefits of using PECA technology integrated in a deployment robot for tank floor inspections.

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NDE 4.0: Opportunities, Challenges, and Global Efforts

Presenting author(s): Dr Ripudaman Singh

Co-Authors:

Room: Pavilion 11 | 9:30 AM Thursday, November 21, 2019

NDE 4.0 is the name, we have now started using to reflect confluence of emerging digital technologies with physical inspection phenomenon. The key ingredients of the cyber-physical NDE systems, will be Internet of Things, Robotics and Automation, Machine Learning, Augmented reality, Additive manufacturing, 5G usage, and many more. Different thought leaders have included other disruptive technologies. The case as it may be, the 4th Industrial Revolution in inspection systems offers unprecedented gains, unforeseen challenges, and demand a coordinated effort to manage the threats and risks of inaction. Primary opportunity in inspection systems comes in form of improved probability of detection (POD) from reduction in human factors; we can expect a steeper POD curve, in which reliability will be getting closer to capability. Second benefit is in terms of asset-customized inspection and maintenance program to concurrently optimize availability-cost-risk. Automation will help with inspector health and safety by managing exposure to uncomfortable situations. All these will add up to provide overall economic gains to all stake holders of the critical infrastructure. These gains, of course, come with many more challenges than we can perceive as of now. System connectivity is easier said than done. Data exchange protocols need to evolve to a whole new level in terms of data interpretation, speed, and security. Just like HTML had to appear for effective explosion of internet. Existing workforce re-training will require a conscious investment on the part of employers as well employees. Acceptance of new technological systems, while existing systems must continue to operate and deliver to the promise of safety and availability is probably less of a concern. Just like the previous industrial revolutions, only the adaptive will survive this one. ASNT must play a role to guide the industry. During the Spring 2018 Research Symposium and Fall 2018 Annual Conference, author presented the case for NDE 4.0, leading up to creation of a committee on the topic at the Spring 2019 Symposium. Johannes Vrana of DGzFP is leading with the formation of an NDT4.0 Committee and a push for similar efforts at the ICNDT. Meyendorf is driving for a Handbook of NDE 4.0 to facilitate awareness and guidance. This presentation will be in sequel to these efforts with further call for action to collectively address the need and challenges in NDE 4.0.

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Optimized Ultrasonic Examination and Calibration Techniques for Longseam Welds

Presenting author(s): Mr Paul Holloway

Co-Authors: Mr Francios Lachance, Mr Andrew Robinson

Room: Pavilion 9 | 10:00 AM Thursday, November 21, 2019

Ultrasonic examinations of longseam piping welds are complicated by curved pipe geometry. Predominantly, the inside diameter creates a “moving target” that increases in distance and reflection angle as the diameter decreases and thickness increases. As well, the beam will diverge after the first reflection which reduces beam density and increases attenuation. Accurate placement of indications around a curved pipe benefits greatly from curved surface correction algorithms but these algorithms do not address sensitivity variations caused by beam divergence. These variations must be carefully controlled by selecting a calibration block with a diameter and thickness representative of the test surface. This paper reviews the ASME limits for calibration blocks over a wide range of pipe sizes and quantifies the amplitude variations using CIVA simulations and experimental testing. The results are then used to devise limits for the design of new compound calibration blocks made specifically for longseam weld inspection in piping according to ASME Sec. V Art. 4. The diameter and thickness ranges in the new block set are compared to the standard ASME limits and the improvement in sensitivity accuracy is quantified. Additionally, advanced software algorithms available for phased array are discussed which include controlled beam density to offset loss of resolution due to beam divergence off the inside diameter, as well as a curved surface plotting algorithm which can overlay the curved pipe geometry on a phased array S-scan presentation. Both are useful to improve resolution, characterization and positioning of flaws. Combining enhanced longseam calibration blocks with advanced phased array software provides an optimized solution for examination of longseam welds in piping.

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Heat Exchanger Tubing Inspection: Improved Asset Integrity Management

Presenting author(s): Mr Olivier Lavoie

Co-Authors: Mr Jonathan Berthier

Room: Pavilion 10 | 10:00 AM Thursday, November 21, 2019

Shell and tube heat exchangers are used to heat and cool various fluids in a wide spectrum of industries. This is especially critical to the power generation and petrochemical industries where the reliability of fixed equipment is paramount. For decades, the industry has relied on conventional tubing probes (i.e. relatively simple sensors) and manual push-pull operations to inspect heat exchanger tubes. It has proven to be an effective way to detect a wide variety of defects, with variable consistency. Indeed, conventional probe designs are typically limited when it comes to sizing indications and/or detecting cracking defects. Manual inspections also come with limitations in terms of speed, data quality, and repeatability, without offering precise defect positioning along the tubes. All these factors – at play during data collection – put an additional burden on analysts, which are typically under pressure to deliver conclusions as to whether or not the fixed asset is fit for service. This paper discusses a comprehensive solution that allows for optimization of acquisition and analysis time, with improved data resolution and accurate defect positioning. Doing so, it is possible to conduct efficient data correlation between inspection techniques, along with insightful data trending, for optimal asset integrity management.

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Panel on NDE 4.0

Presenting author(s): Dr Johannes L Vrana

Co-Authors:

Room: Pavilion 11 | 10:00 AM Thursday, November 21, 2019

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TFM live imaging of a 30-inch Forged Steel Block

Presenting author(s): Mr Frederic Dupont

Co-Authors:

Room: Pavilion 9 | 10:30 AM Thursday, November 21, 2019

Phased array inspection of large forged steel blocks (more than 30-inch in each direction) is very challenging because of the long propagation distances and the variations in the material which affect ultrasound propagation. Also, common phased array technics used for Non-Destructive Testing such as beam focusing are not suitable because focusing will result in very small focused zones compared with the size of the part under inspection. For these reasons, Total Focusing Method (TFM) associated with Full Matrix Capture (FMC) which is naturally focused by the transducer appeared to be the most appropriated method for imaging of defects in such parts. In this work the material was studied and used to design a transducer optimised for the inspection large parts. Elements size and number was a strong concern because of the natural focus of FMC and the large amount of data generated and treated for TFM reconstruction. The aim was to maximise data cost in order to perform live imaging without compromising the resolution. Emission and reconstruction were optimised to increase Signal to Noise Ratio (SNR) using coded excitations and an optimised TFM algorithm. Finally, live imaging of 1/16” Side Drilled Holes in a 30-inch depth forged block was performed. For each reflector, the 6-dB drop extend was lower than 0.2” and 0.05” for respectively the lateral and the vertical peak reconstruction. The SNR was higher than 32 dB and the maximum value of 67 dB was measured at the half depth of the block which confirmed the design of the probe.

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The Importance of Ultrasonic Beam Profiles

Presenting author(s): Mr Jack J Bryant

Co-Authors:

Room: Pavilion 10 | 10:30 AM Thursday, November 21, 2019

Many of the inspection requirements for drill pipe revolve around the use of ultrasonics and sophisticated Full-Length Ultrasonic Testing (FLUT) systems. Drill pipe (a class of oil country tubular goods - OCTG), is a hollow tube usually made from steel, or aluminum, alloys to which threaded connections are attached on each end and when in use supplies drilling torque and fluid to the drill bit. During this process, failure mechanisms, such as cracks, corrosion pits, slip cuts, gouges, etcetera, can be introduced into the drill pipe thus requiring inspection. A typical FLUT system’s operation consist of the drill pipe being loaded into a station of polyurethane rollers and, while the drill pipe is rotating, a scanning device is moved parallel to the tub axis. Concerns with any FLUT system are coverage, accuracy, and repeatability during the inspection process which are linked to the transducer’s effective beam width and therefore requires a transducer beam profile (BP). Why are BP’s so important? This presentation will attempt to highlight the ultrasonic beam characteristics as they pertain to rotating FLUT units as illustrated by typical reference standards used within the industry, which may lead to an understanding of the importance of BP within the inspection process.

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Panel on NDE 4.1

Presenting author(s): Dr Johannes L Vrana

Co-Authors:

Room: Pavilion 11 | 10:30 AM Thursday, November 21, 2019

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Automated Laser Shearography NDT Inspection of Aerospace Components: Future Trends and Challenges

Presenting author(s): Mr Liam John Crosbie

Co-Authors:

Room: Pavilion 9 | 1:00 PM Thursday, November 21, 2019

The capability of effectively and efficiently detecting defects in aerospace structures using Laser Shearography is well known. The technology can deployed for the detection of an array of defects; including; disbonds, delaminations, kissing bonds, cracked cores, crushed cores, ingresses and foreign-object-damage (FOD) in laminates, honeycombs, foam-cores and bonded components. Shearographic systems have continuously been automated into gantries and onto robotic arms since the turn of the century for an array of aerospace applications, including; fairings, nacelles, cowlings, radomes, helicopter blades, pressure vessels, tanks and control surfaces. The advantage of performing repeatable Laser Shearography NDT inspections with high inspection rates that yield traceable and reproducible measurement results is a truly time-efficient and thus cost-effective solution. Future trends and challenges within the aerospace industry for the automation of quality control solutions are vast. Flexile solutions for a growing diverse array of testing applications require the provision of agile robotic integration. Measurement data must be stored within formats that complement and are compatible digital (virtual) models. Validation of test results must be determined based upon user-defined specified tolerances. Reliable measurements is an absolute prerogative for any NDT technology, this is in itself a challenge of which Dantec Dynamics has the solution for your testing application.

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Optical Gas Imaging: A Visual Aid for Leak Detection

Presenting author(s): Mr Ronald D Lucier

Co-Authors:

Room: Pavilion 10 | 1:00 PM Thursday, November 21, 2019

The application of Optical Gas Imaging (OGI) emerged commercially in 2005 with the introduction of portable thermal imagers filtered for the detection of Hydrocarbons. Industry and US EPA cooperated in the deployment of this technology with the goal of reducing fugitive emissions. A report from US EPA in 2016 declared that OGI is the Best System for Emissions Reduction (BSER). EPA issued regulation NSPS OOOOa which requires affected industry to locate and document their leaks via OGI. This technology is currently widely used in the Oil, Gas, Chemical and Electric Utility industries. This paper will provide a fundamental understanding of the science of OGI not only for Hydrocarbons but also where it could be used with trace gases such as Carbon Dioxide and Sulphur Hexafluoride. Case histories and examples of this innovative non-destructive examination will be presented.

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Intelligence Augmentation and Human Machine Interface (HMI) Best Practices for NDT 4.0 Reliability

Presenting author(s): Dr John C Aldrin

Co-Authors:

Room: Pavilion 11 | 1:00 PM Thursday, November 21, 2019

Industry 4.0 refers to a 4th industrial revolution, expected to be based on connected cyber-physical systems, such as the Internet of Things (IoT). There is a parallel vision for the next-generation of NDT capability referred to as NDT 4.0. The most important aspect of the integration of NDT 4.0 is leveraging automation in the evaluation of a part under test and connecting the part state with life cycle management. In recent years, advances have been made in the field of machine learning and artificial intelligence (AI), primarily through developments in deep learning neural networks (DLNN). Challenges however exist with transitioning emerging DLNN algorithms directly for NDT applications. Training deep learning neural networks requires very large, well-understood data sets, which is frequently not available for NDE applications. As well, there are significant concerns about the reliability and adaptability of such algorithms to completely perform complex NDT data review tasks performed by operators today. As a counterpoint to AI, intelligence augmentation (IA) refers to the effective use of information technology to enhance human intelligence. While attempting to replicate the human mind has encountered many obstacles over the years, IA has a much longer history of success. This talk will introduce a series of best practices for intelligence augmentation for NDT applications, highlighting how the operator should interact with NDT data and algorithms. Algorithms clearly have a great potential to help alleviate the burden of ‘big data’ in NDT; however, it is important that operators are involved in necessary secondary indication review and the detection of rare event indications not addressed well by typical algorithms. Several past examples of transitioning algorithms for NDT applications will be presented, emphasizing the successful interfacing of operator and software for optimal data review and decision making. Going forward, advances are needed to efficiently validate NDT techniques that leverage both human and algorithms for data review, and address appropriate process controls and improved software design to ensure optimum performance.

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Understanding Defects

Presenting author(s): Mr Stuart A Kleven

Co-Authors:

Room: Pavilion 9 | 1:30 PM Thursday, November 21, 2019

The discussion will address definitions of the various terms used, such as indication, discontinuity, relevant, non-relevant, true and false indication, linear and rounded defect, and aspect ratio. Three specific areas will be highlighted with regard to causes of defects; inherent, processing related and service related types. The importance of understanding the various steel making and manufacturing processes that can cause indications and what to expect or anticipate from each process will be reviewed as well. Numerous examples of each type of defect will be presented to demonstrate what type of response NDT obtains from the various manufacturing methods and steel making processes as well as service failures.

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Screening for Sulfur, Wear Metals, and Additive Elements in Fuel Oil Using Handheld X-Ray Fluorescence (HHXRF) Analyzers

Presenting author(s): Mr Dillon McDowell

Co-Authors:

Room: Pavilion 10 | 1:30 PM Thursday, November 21, 2019

In situ fuel oil testing is a critical task for machine and engine operators. Stricter global air pollution regulations require that sulfur content in fuels be carefully monitored, while the analysis of wear metals and fuel additives helps avoid costly downtime from engine failures. Energy dispersive X-ray fluorescence (EDXRF) is a common technique for these analyses. In the past, this was done on benchtop EDXRF systems. More recently, the improved performance of handheld X-ray fluorescence (HHXRF) analyzers enables them to be used instead of benchtop systems. In this paper, we demonstrate that HHXRF can appropriately measure sulfur at low levels, in accordance with ASTM D-4294. We also show that HHXRF can detect various wear metals and additive elements at low ppm levels that are comparable to several modern benchtop systems.

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How Small NDE Service Providers Can Use NDE 4.0 As A Competitive Advantage

Presenting author(s): Mr Johannes Kraijesteijn

Co-Authors:

Room: Pavilion 11 | 1:30 PM Thursday, November 21, 2019

Industry 4.0 and NDE 4.0 offer NDE service companies tremendous opportunities. Smaller NDE service providers in general do not have the resources and budgets for innovation and advanced research and development. However, this does not have to be a constraint as access to new developments and new technologies has never been greater. This presentation will explore and provide examples of how NDE 4.0 can support (smaller) NDE service providers to stay ahead of the competition and use NDE 4.0 as a competitive advantage. Examples of topics covered in the presentation are: • Buying versus renting/leasing of advanced inspection equipment. To stay current and make use of the latest technologies renting or leasing of equipment might be a more economical solution. • Hiring versus contracting. Certain tasks can easily be contracted instead of putting someone on the payroll. Think about development of IT systems, programming of inspection software applications, etc. • Automated inspection systems. Automation can provide better and more accurate inspections. • Robotic inspections and drone technology. Used for remote access, confined space, etc. • Explore alternate NDT methods for ‘standard’ inspections. How to change ‘we have always done it this way’. • How to manage and possibly market large sets of inspection data that is collected daily. • Teaming arrangements/strategic alliances with companies that do have departments focusing on innovation and R&D can provide access to new technologies and applications. • Remote access by experts to provide on-site expertise and direct feedback to the inspector. • 3-D printing to support in-house inspection applications.

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Flaw Detection Using Large-Standoff Thermography

Presenting author(s): Dr Steven M Shepard

Co-Authors: Ms Maria Frendberg Beemer

Room: Pavilion 9 | 2:00 PM Thursday, November 21, 2019

The most widely used configuration for performing NDT using active thermography is an IR camera and a heat source placed in close proximity to the target surface (~ 1 ft), typically augmented by a computer, tablet or display device. This arrangement optimizes the output of the excitation source and resolution of the camera, and can often be reduced to a compact footprint that is easily moved over a large part manually, or using gantry or robot. Recently, a system based on Large Standoff, Large Area Thermography (LASLAT) has been successfully deployed for inspection of large structures in the aerospace industry. The system uses optical step heating as an alternative to Flash Thermography (FT), and operates at a standoff distance in the 8-15 ft. range. It provides a larger field of view than FT, and offers a distinct advantage for large structure NDT, since the system can interrogate a large area from a stationary position by moving the field of view over the target surface using pan and tilt degrees of freedom, eliminating the need for a gantry system or robot. The primary consequence of using LASLAT instead of FT is that because LASLAT requires a longer excitation (~seconds) than flash (~milliseconds), there is a “blind period” during step excitation during which reflected IR from the source contaminates the IR signal, which may complicate precise depth measurement of near surface flaws or inspection of high conductivity metals. However, for many composite structures, after Thermographic Signal Reconstruction (TSR) processing, LASLAT and FT performance is comparable. In this paper, we use a commercial FT system as a baseline to evaluate the flaw detection capability of LASLAT based on Signal-to-Noise Ratio (SNR), flaw size measurement and resolution on a carbon-fiber composite panel with intentional flaws that span aspect ratios 1-17.

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When Pod and Speed Matter: A Novel Eddy Current Array Tool to Track Down Stress Corrosion Cracking on Pipelines

Presenting author(s): Mr Michael Sirois

Co-Authors: Mr Mathieu Bouchard

Room: Pavilion 10 | 2:00 PM Thursday, November 21, 2019

For years, Magnetic Particle Inspection (MPI) has been the established method to detect Stress Corrosion Cracking (SCC) during pipeline integrity digs. Although this method is widely available and relatively inexpensive, it remains time consuming and results are highly operator-dependent. Indeed, numerous factors – including human factors – have an adverse effect on the results of an MPI examination during the SCC screening process: extent of the area to be assessed (tied to inspector motivation and capabilities), difficult positioning underneath pipes in ditch (12 o’clock position being critical), inadequate surface preparation, lack of contrast, and condensation on pipes are good examples. Numerous recent field trials have proved that a novel Eddy Current Array (ECA) solution can systematically outclass MPI on many aspects in the field. Conclusions lead to believe this alternative method has the potential to become the new reference for SCC detection on pipelines during integrity digs. With an impressive speed combined to a particularly high Probability of Detection (PoD), the new ECA system can transform the way the industry performs direct assessment for SCC. Above all, it offers an opportunity to control the human factors like never before. This paper discusses a complete, novel ECA solution for in-ditch SCC detection on pipelines and presents results from the field. It compares ECA with MPI on several aspects, and demonstrates how ECA compares favorably, improving the overall screening process efficiency during in-ditch examinations.

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Building Sustainable Business Models and Strategies Towards NDT 4.0

Presenting author(s): Mr Ramon S Fernandez Orozco

Co-Authors:

Room: Pavilion 11 | 2:00 PM Thursday, November 21, 2019

ABSTRACT Every industrial revolution in history has reshaped not only the production methods, the economy and finances but also has had profound implications in human relations, education, and social behaviors. Companies are currently struggling worldwide to catch-up, understand and capitalize Industry 4.0 and now there is already talk within research and technology institutions of Industry 5.0. An important number of actors within our industry, including ASNT, are moving ahead in anticipating and shaping a series of initiatives and toolsets that will configure and evolve not only the face of NDT 4.0 but its heart and soul. Building competitive and sustainable business models, value propositions and strategies towards NDT 4.0 is a challenge ahead not exclusive for business leaders and CEOs in our industry but a compulsory skill necessary to all NDT practitioner to help him/her consolidate and reinvent his/her professional careers. In the following years the focus and scope of the role of NDT technicians in several industries will be transformed and a supplementary set of skills will be necessary to face the challenges inherent to this transformation process, but also, what is most important, to capitalize the new opportunities that will also be generated. In this lecture we aim to offer a set of conceptual frameworks and to provide a virtual toolbox, based in our hands-on professional experiences redefining business models, value propositions and strategies in dozens of organizations through business incubation and acceleration programs, to empower business leaders to build new business models and to challenge pre-existing ones and a to help NDT professionals to cope and capitalize the disruptions ahead facing them with optimism and increased confidence.

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Assessment of a fatigue state of constructional metal by non-destructive method based on measurements of its magnetic characteristic, namely – coercive force. Practical results

Presenting author(s): Mr Roman Solomakha

Co-Authors:

Room: Pavilion 9 | 2:30 PM Thursday, November 21, 2019

The coercive force method(CFM) has three main cases of use. 1st is monitoring effectiveness of technologies in manufacture of new metal products and final acceptance control of mechanical properties in mechanical engineering and metallurgy. The 2nd and 3rd cases are diagnostic tasks of a metal fatigue assessment during operation, including a forecast of a residual service life. The 2nd case is applied in diagnostics of objects from cast irons and ferromagnetic steels. The 3rd – for (initially non-magnetic) steels objects. This case is about 5 years old. In 2nd and 3rd cases there is used a property inherent to coercive force, Hc, which continuously, unambiguously and very noticeably (by 3–4 times) increases from an initial Hc0 condition to a limit H_C^B state in course of development and accumulation of fatigue. Fatigue process in ferromagnetic steels develops through a mechanism of accumulating the microdamages in a crystal lattice to the level when it becomes possible to form the fatigue macrocracks with the subsequent destruction of metal. In stainless steels of austenite class in the as-delivered state there is no magnetism. In such steels fatigue process is manifested in two ways: 1) accumulation of microdamage and simultaneous 2) a decay of austenite with the appearance of ferromagnetic products of this decay according to the diagram «iron-carbon». As a result fatigue magnetism appears. These mechanisms act together not contradicting each other in the display of the process of fatigue development in such steels. This acquired ferromagnetism grows in process of its accumulation and is independent measure of the fatigue degradation of initially non-magnetic metal. It makes possible to measure the level of fatigue microdamage by using coercive force method. Without use of this «fatigue» magnetism as a transmitter and converter of information on degree of fatigue micro-damage it would not be possibly to assess this damage in practical diagnosis. Practice shows that a good coercimeter is more accurate and more sensitive to fatigue transformations in austenitic metal than the best ferritometer. Coercitimetry today is the only effective method for monitoring metal fatigue, simple and inexpensive. Fatigue cracks physically can be formed only after accumulation in metal of fatigue degradation to a certain level. Assessment of a current metal state performed only regarding a presence of defects, without taking into account fatigue, is not complete and consistent for the prediction of metal performance. The fatigue concentration zones are detected coercimetrically more reliably than by any defectoscopy method. Defectoscopy in zones with insufficient fatigue is a useless procedure. Fatigue cracks in such zones cannot exist. Coercimetric diagnosis of fatigue windpower tower, cowper, rectification column, hulls of sea vessels illustrate the report accompanied by results of destructive bench fatigue tests of different steels samples.

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The application of long range ultrasonic testing (LRUT) for examination of Crack, Wear, Fatigue Stress and Corrosion on Turbine Shaft.

Presenting author(s): Mr Hussain Jafari

Co-Authors:

Room: Pavilion 10 | 2:30 PM Thursday, November 21, 2019

Abstract LRUT (Long range ultrasonic testing) is a rapid way of screening for corrosion in pipelines in oil, gas and petrochemical industries. LRUT is performed using a system which is made up of a low frequency flaw detector, a pulsar receiver unit, some transducer rings, and a laptop computer which contains the software that controls the system. The technique differs from conventional ultrasonic testing, in this method, when generated in pipes these plate waves are known as guided waves. This method of NDT is available for difficult or impossible condition of test (e.g. where the pipe is buried, insulated, sleeved elevated on pipe racks, etc. LRUT provides information about the presence of flaws and their location along the pipe. This paper presents the methodology of using LRUT on Turbine Shafts, LRUT have many significant capability that by that capability we can inspect the considerable and sensitive shafts like turbine shaft, for example LRUT can test up to 100 meters screening distance on pipelines, the we can most of shafts by different long around 100 meters. LRUT can Focusing capability to evaluate corrosion distribution around pipe circumference, by this ability we can inspect and find damage, corrosion distribution and crack on around surface of shaft. LRUT have ability to Testing of pipe from 2” up to 48” diameter then LRUT have ability to testing of shaft in different diameters. And one of special and unique capability of LRUT is possibility to do test shaft with don’t need to Disassemble of turbine. Also LRUT can detection of metal loss > 3%, this ability of LRUT is very useful to find detection on shaft surface. And finally LRUT can more than 100 times faster than traditional ultrasonic methods and Low cost screening with 100% coverage and available to test inaccessible sections.

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The Operational Value of Digitizing the NDT Inspection Process

Presenting author(s): Mr Bruce Breeden

Co-Authors:

Room: Pavilion 11 | 2:30 PM Thursday, November 21, 2019

Operational efficiency and effectiveness are critical to service providers conducting NDT inspections. Meeting customer timelines, accurate data collection, inspection report format and cost are critical customer requirements. The service provider must compete in the market with safety performance, job margin, productivity, invoice cycle time, equipment asset tracking and internal workflow optimization. Addressing the inspection process and expectations from an end-to-end view and digitizing the process transforms business operations. Results include increased customer satisfaction, greater employee engagement, enhanced safety, quicker and more accurate inspection reports, and improved job margins and billing cycle times. This technical presentation will provide an overview of the digital architecture required and the impact on correlated business operations reports: resource utilization, asset tracking, sales quoting accuracy, profit and loss statements, margin control, customer reports, technician safety and engagement, internal department inspection report workflow, and invoice cycle time. This technical presentation will also review how to approach digital transformation by mapping the end-to-end process and critical digital transformation steps to achieve these outcomes.

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Current Challenges Facing Nondestructive Evaluation of Additively Manufactured Parts and Surfaces

Presenting author(s): Mr Adam Brooks

Co-Authors:

Room: Pavilion 9 | 3:30 PM Thursday, November 21, 2019

Nondestructive evaluation (NDE) is playing a key role in the field of additive manufacturing (AM). With complex part geometries, unique processes, and a wide variety of materials, the ability to non-destructively observe part quality, feature sizes, and defect locations provides insight into the optimization of an additive process. As there are many NDE techniques currently used for AM part characterization such as X-ray CT (XCT), confocal microscopy, and white light interferometry, the need to understand the benefits and problems associated with these and other techniques for additive parts is high. Several current NDE challenge areas include the dimensional accuracy of XCT scans for porosity analysis, understanding the surface texture of an as-built part versus a surface finished part, and determining the probability of detection for part defects. This talk will address several of these topics and provide a look at new inspection methods to observe AM parts. EWI’s background is in AM process development and metrology & inspection, where optimization and understanding of the AM process chain occurs from start (powders) to finish (final parts). EWI is also a founding member of the ASTM Center of Excellence (CoE) working on active R&D to accelerate and transition research into usable standards. Current work focuses on developing a guide for AM surface texture measurement, characterization, and metrics (WK66682). By showing how AM surfaces vary greatly from traditional wrought material, guidelines will be provided on how to ensure accurate and reliable surface measurements for AM parts.

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Structural Health Monitoring using Guided Waves

Presenting author(s): Mr Sang Y Kim

Co-Authors: Ms Heui K Kim

Room: Pavilion 10 | 3:30 PM Thursday, November 21, 2019

Permanently installed monitoring sensor (PIMS) using guided waves has been developed and installed for structural health monitoring of pipeline. Monitoring of structure can be done in 2 ways:1) Permanently installing a magnetostrictive strip on structure, and 2) Permanently installing both magnetostrictive sensor and monitoring terminal. The first method is cost effective way of guided wave monitoring and has merit of acquiring data at multiple center frequencies by changing the probes if the testing location is easily accessible. The second monitoring method using magnetostrictive sensor (MsS) PIMS is much stable monitoring method and it is effective on requiring large portion of access cost for inspection. The results of both methods are compared for integrity monitoring of structure.

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Putting the Meta into Metadata

Presenting author(s): Mr David S Forsyth

Co-Authors:

Room: Pavilion 11 | 3:30 PM Thursday, November 21, 2019

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Additive Manufacture and Nondestructive Testing of Aerospace Components

Presenting author(s): Mr Stuart A Kleven

Co-Authors: Mrs Jennifer Anaya

Room: Pavilion 9 | 4:00 PM Thursday, November 21, 2019

The use of additive manufacturing is rapidly coming of age in the manufacture of complicated aerospace parts. In particular, parts with many internal features that were normally machined from forged blocks or cylinders are being manufactured using direct energy additive processes. Forged blanks involved the removal of an excessive amount of material and some very expensive multi-axis machining. The use of additive has greatly reduced the amount of machining and metal required. With the advent of these new manufacturing processes comes the uncertainty concerning the quality of the components. In many cases, normal nondestructive methods have not been able to identify flaws due to location and/or orientation within the product. The new additive manufacturing methods have introduced new types of flaws that are specific to the new manufacturing methods. This paper will address a case study and will show test methods that were able to reliably identify indications and provide feedback to the manufacturing and design engineers on the project. It also involves some lessons learned.

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A Continuous Guided Wave Ultrasound Testing Technique on Piping and Tubing

Presenting author(s): Mr Teguewinde Sawadogo

Co-Authors: Mr Krassimir Stoev

Room: Pavilion 10 | 4:00 PM Thursday, November 21, 2019

Ultrasonic guided waves have been employed for decades for nondestructive testing in plate- and pipe-like structures. The tests are usually conducted in pulse-echo mode, whereby pulsed ultrasonic guided waves are generated and transmitted along a structure in which presence of discontinuities is revealed through their reflection of the transmitted waves. Estimation of the time-of-flight of the pulsed waves from the transmitter to the reflector and back to the receiver is used in conjunction with knowledge of the wave speed in the structure to estimate the position of the discontinuity which can be a flaw, an insert, a protuberance or simply the end of the structure. Despite its widespread usage and relative success, the pulsed ultrasound inspection method has known deficiencies, such as: (i) spatial resolution is pursued at the expense of pulse duration and hence transmitted energy; (ii) pulsed signals typically have a low duty-factor, limiting the amount of energy used to stimulate the object under test; and (iii) achieving acceptable signal-to-noise ratio (SNR) usually requires increasing the amplitude of the pulses, which would lead to reducing life-expectancy of the transducers. In this study, a continuous wave frequency-domain reflectometry method is used in conjunction with guided waves for nondestructive testing in plate- and pipe-like structures. The continuous wave method employed in this study consisted in generating a frequency modulated signal, a portion of which being amplified and sent along the structure while the remaining portion is mixed with the reflected signal. The resulting signal is then low-pass filtered and Fast-Fourier transformed to isolate peak frequencies associated with features of the structure. Experiments were conducted in piping and tubing where circumferential flaws were successfully detected. The continuous guided wave ultrasound testing technique is described in the study and the results of the experiments presented.

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Case studies of NDT 4.0 in the oil and gas industry

Presenting author(s): Mr Casper Wassink

Co-Authors: Mr Marc Grenier

Room: Pavilion 11 | 4:00 PM Thursday, November 21, 2019

Examples of Industry 4.0 usually focus on manufacturing or logistics. While these are also important disciplines in the Oil and Gas industry, it is not the first thing that comes to mind when addressing the challenges related to safety and asset integrity. However, technologies that are commonly associated with Industry 4.0, such as supply chain management solutions, robotics, additive manufacturing and big data also have a big role in NDT. The owner-operators of Oil and Gas related installation certainly support his trend and routinely request these technologies to be applied to NDT. This paper will explore how the discourse on Industry 4.0 applies to NDT 4.0 and how the trending technologies mentioned above play a role in innovations offered by Eddyfi Technologies. This will be done, by showing where the technologies have been applied in R&D efforts currently underway at different Eddyfi brands. The first case study focusses on tubes testing, the technology that Eddyfi was originally founded on 10 years ago. The second focusses on storage tank inspection. The case studies will highlight how applying NDT 4.0 contributes to increased NDT quality, and ultimately to safety and asset integrity in the Oil and Gas industry.

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Employing Computed Tomography in the Development & Qualification of AM Processes & Products

Presenting author(s): Mr Brett A Muehlhauser

Co-Authors:

Room: Pavilion 9 | 4:30 PM Thursday, November 21, 2019

Computed Tomography (CT) has become an extremely valuable tool in helping to expedite these qualification processes. CT is being employed in applications ranging from new AM process development through final inspection of product. Extensive studies have been performed using CT to help detect, classify and better understand the types and sizes of discontinuities found within various AM processes. Various In-situ monitoring methods employed during the AM printing cycle can provide valuable information about the AM build and the product integrity. These monitoring processes however need to be qualified. CT is now the method of choice in helping provide a three-dimensional correlation of CT identified defects to the in-situ recorded events. Critical product applications not only demand confidence in the internal integrity of the product but also in the internal and external metrology data. CT is a technology that can provide both for many applications. AM Product and Sample Coupons are commonly evaluated for material properties such as Tensile, Compression, Torsion and Fatigue. With In-Situ 4D CT, these tests can be performed while CT is being performed via load cell integration within the CT system. This presentation will include examples of CT being applied in the above applications on both metal and polymer AM products. Additionally, the use of CT in the AM process and product qualification will be outlined.

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Sensitivity analysis of the short-range guided wave evaluation of large diameter piping using the GUL QSR1® tool

Presenting author(s): Mr Timothe Falardeau

Co-Authors:

Room: Pavilion 10 | 4:30 PM Thursday, November 21, 2019

Quantitative short-range evaluation using ultrasonic guided waves is a new non-destructive evaluation method which uses shear waves modes, propagating along the circumferential direction of a pipe, to evaluate the minimum remaining thickness of a pipe along its axis. One of the most advanced systems which uses this technology is the QSR1® tool manufactured by Guided Ultrasonics Ltd. The QSR1® uses two electromagnetic acoustic transducers modules, one module set in emission and one module set in reception, to generate acoustic waves at different frequencies in a pipe. In order to perform a full scan, the QSR1® unit is positioned on the top of a pipe, with the transducer modules spaced at an equal distance from the 12 O’clock position, and then driven along the axial direction using integrated electric motors. Once multiple locations have been scanned, the frequency content of the received signals is then processed to determine the cut-off frequency of the SH1 wave mode received, which is directly related to the minimum remaining thickness. Since the QSR1® is only in contact with the top portion of a pipe, the main application of this technology is for the detection of corrosion under pipe supports. As of today, the QSR1® is limited to pipe diameter ranging between NPS 8 to NPS 16 and pipe of thickness ranging between one quarter of an inch to half of an inch. Pipe larger than NPS 16 in diameter are not currently supported by the unit’s manufacturer, but larger diameter frames (NPS 18 to NPS 24) can still be obtained upon request. In this work, the goal of this study was to evaluate the sensitivity of the QSR1® on large diameter piping. The large dimension of the pipe, which increases the width of the ultrasonic beam, and the top spacing between the modules relative to the bottom spacing of the modules, which increases the distance travelled by the ultrasonic wave propagating in the pipe, must be accounted for in order to evaluate the cut-off frequency correctly. The shape, the size and the extent of the defects on a pipe are also parameters which strongly affect the wave modes propagating in the pipe since they are sensitive to the pipe's geometry. Therefore, the variation of the first SH modes (0,1 and 2), the influence of the beamspread and the longer distance travelled by the ultrasonic wave were parameters studied in this work. Multiple type and size of defects were used to evaluate the sensitivity of the QSR1® on large diameter piping. This work focuses on the analysis of the experimental results obtained using the QSR1® on piping ranging from NPS 18 to NPS 24 with different type and size of defects.

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You Already Can Do (some) NDT 4.0: Initial Investigations of the NDT 4.0 Digital Twin Concept Using Ultrasonic Digital Chart Recordings

Presenting author(s): Mr Phillip William Trach

Co-Authors:

Room: Pavilion 11 | 4:30 PM Thursday, November 21, 2019

NDT 4.0 is a rapidly developing subset of the Industry 4.0 paradigm which is currently being explored and implemented throughout industry. One of the core concepts which the NDT 4.0 paradigm includes is the “digital twin”. The digital twin is the entire set of information about the material which has been tested, in a format which is easy to read, easy to distribute, and easy to update and expand. Digital chart recording of ultrasonic testing is a well-established mode of capturing test data. Within the NDT 4.0 paradigm, this data capture takes on new significance. Chart recordings can be quickly and easily uploaded to various locations, including end users’ data storage systems, allowing end users to arrange and correlate the digital charts to the material tested. The purpose of this presentation is to show how existing digital chart recording technology is already capable of generating this part of the digital twin, and how the transmission of the test data can be simple and rapid, allowing end users to acquire, store, and use that part of the digital twin.

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Fully-flexible Thin-film Ultrasonic Array for use in Industrial NDE Applications

Presenting author(s): Mr Dave Hughes

Co-Authors: Blair Rocks

Room: Pavilion 9 | 5:00 PM Thursday, November 21, 2019

Blair Rocks1, Daniel Irving1, Fabrizio Gaudenzi1, David Allan Hughes1 1Novosound Ltd., Biocity, Motherwell, United Kingdom. Ultrasonic arrays have been employed in NDE since the 1980’s. However, with the rise of computer generated, complex, geometrical structures, the demand for arrays able to conform to these structures is more pressing. The work here reports on the development of a truly flexible ultrasound array that allows uninspectable objects to be ultrasonically inspected. A novel, thin-film, piezoelectric material is deposited onto a flexible substrate using reactive sputtering of a metal-oxide-based alloy. Additive manufacturing processes are then employed allowing for the mass manufacture of flexible arrays with consistent acoustic output and build quality, operating in the region of 5-100MHz. The arrays are subsequently demonstrated and tested on a variety of materials with varying geometries such as composite structures and metallic turbine blades. Moreover, these arrays are also demonstrated as permanently installed sensors, providing a solution to improved continuous monitoring. Data presented here includes sensitivity analysis and performance of a 64 element 10MHz ultrasound array. This was carried out using a DPR500 (JSR Electronics) pulse echo system with 140V excitation, and subsequently with a commercial NDT instrument for full phased array imaging. Early results have shown an operation of 7-10MHz with a bandwidth of 67%. Images have been obtained from scanning test objects, comprising metallic and carbon-composite materials, using industry-standard equipment showing ability to inspect complex structures with high resolution across curves, bends and twists at varying thicknesses. Further work will concentrate on the refinement of both the proprietary material and array-manufacture process to improve the signal output and array sensitivity.

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Theoretical analysis of scattered wave amplitude calculation of torsional wave on a pipe

Presenting author(s): Dr Jaesun Lee

Co-Authors: Dr Younho Cho

Room: Pavilion 10 | 5:00 PM Thursday, November 21, 2019

The use of guided waves is widely used in long-distance pipeline testing due to its propagation characteristics with low attenuation characteristics. In addition, recent structural health monitoring (SHM) and condition monitoring (CM) have become major paradigms in the inspection and monitoring of large structures. However, the most important issues in structural monitoring are quantitative defect sizing and signal interpretation. In this study, elastic dynamics were applied to the calculation of the scattering wave amplitude. Reciprocity is a well-established theorem that can formulate complex scattering problems in a simpler way. The torsional wave mode on the cylindrical structure is explored by the theorem of reciprocity. The dispersion amplitude is a function of the incident wave frequency and the defect size. Surface defects with tilt angles are formulated to analyze the relationship between defect angle and wavelength. Wave fields are obtained in an elegant way using superposition techniques and reciprocity theorem. The theoretical results can provide a signal analysis for quantitative defect size determination. Closed solution with torsional wave scattering amplitude can play an important role in quantitative signal analysis. It is expected to be used as the basis for structural condition analysis by SHM and CM approaches.

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Sliding Suction Based NDT Robotic Crawler

Presenting author(s): Mr James Smith

Co-Authors:

Room: Pavilion 11 | 5:00 PM Thursday, November 21, 2019

Traditional inspection techniques in the Chemical industry often require workers to enter confined spaces. Such hazards as poor air quality, exposure to chemical substances, dangerous internal structures to name a few are found in such an environment. Advances in the utilization of Robotics presents a safer, cost efficient and an effective alternative. This session will explore Robotic capabilities, Non Destructive Testing (NDT) techniques, an assessment of techniques and a real world application.

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