In-process calibration of a non-destructive testing system used for in-process inspection of multi-pass welding

Javadi, Yashar; Sweeney, Nina E.; Mohseni, Ehsan; MacLeod, Charles N.; Lines, David; Vasilev, Momchil; Qiu, Zhen; Vithanage, Randika K. W.; Mineo, Carmelo; Stratoudaki, Theodosia; Pierce, S. Gareth; Gachagan, Anthony

doi:10.1016/j.matdes.2020.108981

Cited by 27 publications

(15 citation statements)

References 17 publications

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“…Furthermore, the dynamic nature of multipass welding essentially results in a different thermal gradient after each welding pass. An in-process thermal compensation procedure was proposed in [ 42 ] involving the parallel manufacture of a second, identical sample with an embedded Tungsten pipe, serving as an in-process calibration block. The reflection from the known in size and location pipe was used to calibrate for the effects of the temperature gradients and it was demonstrated that the approach provided more accurate results, compared to a traditional calibration on a sample with a side drilled hole at a uniform temperature.…”

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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“…This phenomenon can be explained by the variation of acoustic wave velocity in solid media, such as steel, with temperature [25]. It was shown in [6,26], that the temperature gradient present after weld deposition caused the ultrasound beams to deviate from their expected path due to the velocity variation and subsequent beam refraction, affecting defect sizing, amplitude and localisation. Calibration trials of the roller-probe at elevated temperature showed a -6.34dB amplitude drop of the received signal amplitude from a 2 mm diameter SDH in a representative weld, at 240 °C compared to room temperature of 22 °C.…”

Section: Effect Of Elevated Temperaturementioning

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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“…(I) Intentionally-manufactured HIC: The idea of intentionally-manufactured weld defect for NDT calibration was used by Javadi et al [5][6][7]. They intentionally embedded tungsten components (ball, rod and pipe) in the weld to validate the performance of a robotic NDT system and also calibrate the inspection parameters.…”

Section: Quantification Challenge In Non-destructive Testing (Ndt) Of Hicmentioning

confidence: 99%

“…The high-temperature PAUT inspection discussed in this paper avoids the necessity to waiting until the weld has cooled down. The high-temperature in-process inspection was developed by Javadi et al [7] and Lines et al [11] in the multi-pass welding. They used the system for inspection of tungsten defects but, because the purpose of the work was the in-process calibration of a high-temperature inspection system, the inter-pass inspection was required to be accomplished in only a few minutes.…”

Section: Quantification Challenge In Non-destructive Testing (Ndt) Of Hicmentioning

confidence: 99%

“…They used the system for inspection of tungsten defects but, because the purpose of the work was the in-process calibration of a high-temperature inspection system, the inter-pass inspection was required to be accomplished in only a few minutes. Otherwise, the weld could be cooled down below the inter-pass temperature (100 °C) which was a requirement for starting the next subsequent pass [7].…”

Section: Quantification Challenge In Non-destructive Testing (Ndt) Of Hicmentioning

confidence: 99%

See 1 more Smart Citation

High-temperature in-process inspection followed by 96-h robotic inspection of intentionally manufactured hydrogen crack in multi-pass robotic welding

Javadi

Mohseni

MacLeod

et al. 2021

International Journal of Pressure Vessels and Piping

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This investigation introduces two new techniques to quantitatively address the challenging problem of understanding Hydrogen Induced Cracking (HIC) in welding processes. The first technique is a novel procedure to create a known and controlled HIC in a welded sample. The second is an in-process monitoring technique to measure the initial formation and subsequent growth of the HIC in a multi-pass weld whilst being compatible with the high temperatures associated with the welding process. The HIC was initiated using a localised quenching method of the weld and its character was verified using both macrograph and microscopic investigations. During HIC initiation and growth, the sample was monitored every 1-30 minutes for a total of 96 hours using a custom non-destructive testing (NDT) system, mounted on a robot which ensured repeatable inspection positioning. Combining these techniques has therefore allowed for the first time, a detailed understanding of the evolution of HIC in a multi-pass welded sample. Our findings reveal that the HIC was initiated 43 minutes after the weld ended and that it then grew rapidly for about 15 minutes and continued growing at a slower rate for around 24 hours. No significant growth was observed for the remaining 72 hours of the experimental measurement.

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In-process calibration of a non-destructive testing system used for in-process inspection of multi-pass welding

Cited by 27 publications

References 17 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

High-temperature in-process inspection followed by 96-h robotic inspection of intentionally manufactured hydrogen crack in multi-pass robotic welding

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