Continuous monitoring of an intentionally-manufactured crack using an automated welding and in-process inspection system

Javadi, Yashar; Mohseni, Ehsan; MacLeod, Charles N.; Lines, David; Vasilev, Momchil; Mineo, Carmelo; Foster, Euan; Pierce, S. Gareth; Gachagan, Anthony

doi:10.1016/j.matdes.2020.108655

Cited by 33 publications

(18 citation statements)

References 13 publications

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“…As the sample cools down, this causes imaging anomalies in both amplitude and position. In [ 38 ], a Tungsten rod was introduced in the weld to form a static reflector of known size and location [ 39 ]. The weld was repeatedly inspected at regular time intervals for a period of 22 h, and the position and amplitude of the inserted reflector were extracted to form a thermal compensation curve.…”

Section: Ultrasonic Inspectionmentioning

confidence: 99%

Sensor-Enabled Multi-Robot System for Automated Welding and In-Process Ultrasonic NDE

Vasilev

MacLeod

Loukas

et al. 2021

Sensors

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The growth of the automated welding sector and emerging technological requirements of Industry 4.0 have driven demand and research into intelligent sensor-enabled robotic systems. The higher production rates of automated welding have increased the need for fast, robotically deployed Non-Destructive Evaluation (NDE), replacing current time-consuming manually deployed inspection. This paper presents the development and deployment of a novel multi-robot system for automated welding and in-process NDE. Full external positional control is achieved in real time allowing for on-the-fly motion correction, based on multi-sensory input. The inspection capabilities of the system are demonstrated at three different stages of the manufacturing process: after all welding passes are complete; between individual welding passes; and during live-arc welding deposition. The specific advantages and challenges of each approach are outlined, and the defect detection capability is demonstrated through inspection of artificially induced defects. The developed system offers an early defect detection opportunity compared to current inspection methods, drastically reducing the delay between defect formation and discovery. This approach would enable in-process weld repair, leading to higher production efficiency, reduced rework rates and lower production costs.

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Section: Ultrasonic Inspectionmentioning

confidence: 99%

Sensor-Enabled Multi-Robot System for Automated Welding and In-Process Ultrasonic NDE

Vasilev

MacLeod

Loukas

et al. 2021

Sensors

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“…Based on the authors' prior work [14], it was observed that the received signal amplitude from an artificially embedded 2.6mm OD tungsten rod defect, of length 38mm in a weld increased by 4.08 dB when the sample cooled down from 164 °C to 28 °C. Also, for the same reference temperature boundaries, the defect position on a sector scan image moved by approximately 3 mm.…”

Section: Effect Of Elevated Temperaturementioning

confidence: 99%

“…Therefore, this work aims to expand the scope of previous research carried out on in-process inspection of multipass welds by introducing a novel phased array ultrasound roller probe that can be deployed robotically [7,14]. A typical roller probe is an ultrasound inspection device that encompasses a single element or PAUT transducer within a wheel [15].…”

Section: Introductionmentioning

confidence: 99%

A Phased Array Ultrasound Roller Probe for Automated in-Process/Interpass Inspection of Multipass Welds

Vithanage

Mohseni²,

Qiu³

et al. 2021

IEEE Trans. Ind. Electron.

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“…It provides coverage for a large area of interest, spans full-eld information, requires no tool for testing specimens contact, and a fast based process [6][7][8][9]. It has been used to detect small surface cracks and porosity in metal plate welds between 5-10 µm wide [10][11][12][13][14]. Thermography can be used for the detection of corrosion, fatigue defects and damage [15,16].…”

Section: Introductionmentioning

confidence: 99%

In-Situ Passive Infrared Thermography Application for the Assessment of Localized Mechanical Properties of TIG-Welded Inconel 625 Alloys

Rawashdeh¹,

Atieh²,

Bani-Mostafa³

2021

Preprint

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Traditional evaluation of weld joint mechanical properties by destructive testing shows the limitations of these evaluation methods, including equipment limitations, high materials/testing cost, and challenging repeatability. This work presents an experimental approach for utilizing passive infrared thermography and tensile testing to evaluate the correlation between thermal and localized TIG-welded Inconel 625 joints' mechanical properties. The results show that different areas of interest behave differently during the tensile test. The dog-bone shaped TIG-welded samples were divided into five regions of interest on both sides of the weldment, of which two are repetitive on both sides of the sample representing Inconel 625 base metal alloy, heat-affected zones, and weld beads. The temperature change rate in these three regions varied from 0.17oC/min to 0.67oC/min as the tensile test progresses. The fractography analysis showed that the failure occurred within the weld beads, even though the highest temperature was observed in the heat-affected zones, suggesting higher strength in the heat-affected zones. This work's suggested evaluation method provides a powerful industrial and experimental tool to predict weld failure based on temperature changes during static loading.

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Continuous monitoring of an intentionally-manufactured crack using an automated welding and in-process inspection system

Cited by 33 publications

References 13 publications

Sensor-Enabled Multi-Robot System for Automated Welding and In-Process Ultrasonic NDE

Sensor-Enabled Multi-Robot System for Automated Welding and In-Process Ultrasonic NDE

A Phased Array Ultrasound Roller Probe for Automated in-Process/Interpass Inspection of Multipass Welds

In-Situ Passive Infrared Thermography Application for the Assessment of Localized Mechanical Properties of TIG-Welded Inconel 625 Alloys

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Continuous monitoring of an intentionally-manufactured crack using an automated welding and in-process inspection system

Cited by 33 publications

References 13 publications

Sensor-Enabled Multi-Robot System for Automated Welding and In-Process Ultrasonic NDE

Sensor-Enabled Multi-Robot System for Automated Welding and In-Process Ultrasonic NDE

A Phased Array Ultrasound Roller Probe for Automated in-Process/Interpass Inspection of Multipass Welds

In-Situ Passive Infrared Thermography Application for the Assessment of Localized Mechanical Properties of&nbsp;TIG-Welded Inconel 625 Alloys

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In-Situ Passive Infrared Thermography Application for the Assessment of Localized Mechanical Properties of TIG-Welded Inconel 625 Alloys