In situ detection of welding defects: a review

Madhvacharyula, Anirudh Sampath; Pavan, Araveeti V Sai; Gorthi, Subrahmanyam; Chitral, Srihari; Venkaiah, N.; Kiran, Degala Venkata

doi:10.1007/s40194-021-01229-6

Cited by 49 publications

(37 citation statements)

References 110 publications

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“…As these phenomena happen inside a material, a specific amount of energy discharges rapidly resulting in the generation of transient elastic waves. The elastic waves travel within the material to the surface and can be detected in real time using sensors, e.g., a piezoelectric transducer in conventional AE, mounted on the surface of the tested material or via vibrometers [ 42 , 70 ]. Transducers convert the generated mechanical motion on the surface into the electrical signal.…”

Section: Acoustic Emissionmentioning

confidence: 99%

A Review of Non-Destructive Testing (NDT) Techniques for Defect Detection: Application to Fusion Welding and Future Wire Arc Additive Manufacturing Processes

et al. 2022

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In Wire and Arc Additive Manufacturing (WAAM) and fusion welding, various defects such as porosity, cracks, deformation and lack of fusion can occur during the fabrication process. These have a strong impact on the mechanical properties and can also lead to failure of the manufactured parts during service. These defects can be recognized using non-destructive testing (NDT) methods so that the examined workpiece is not harmed. This paper provides a comprehensive overview of various NDT techniques for WAAM and fusion welding, including laser-ultrasonic, acoustic emission with an airborne optical microphone, optical emission spectroscopy, laser-induced breakdown spectroscopy, laser opto-ultrasonic dual detection, thermography and also in-process defect detection via weld current monitoring with an oscilloscope. In addition, the novel research conducted, its operating principle and the equipment required to perform these techniques are presented. The minimum defect size that can be identified via NDT methods has been obtained from previous academic research or from tests carried out by companies. The use of these techniques in WAAM and fusion welding applications makes it possible to detect defects and to take a step towards the production of high-quality final components.

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Section: Acoustic Emissionmentioning

confidence: 99%

A Review of Non-Destructive Testing (NDT) Techniques for Defect Detection: Application to Fusion Welding and Future Wire Arc Additive Manufacturing Processes

et al. 2022

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“…In a typical service rail vehicle load‐bearing structure, the primary structures are usually connected by a metal inert gas (MIG) welding process. The high‐stress concentration at the weld, residual stresses, geometry, and weld quality makes the load‐bearing structure more susceptible to fatigue failure 1–3 . Typical failure modes are classified as weld root and toe 4 .…”

Section: Introductionmentioning

confidence: 99%

“…The high-stress concentration at the weld, residual stresses, geometry, and weld quality makes the load-bearing structure more susceptible to fatigue failure. [1][2][3] Typical failure modes are classified as weld root and toe. 4 Cracking starts at the weld root and extends through the weld, called root cracking.…”

Section: Introductionmentioning

confidence: 99%

Fatigue life prediction of aluminum alloy T‐welded joints root failure based on equivalent crack method

Wang

Yang

Zhu

et al. 2023

Fatigue Fract Eng Mat Struct

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This study proposes an equivalent crack life prediction method for root cracks in T‐welded joints. An equivalent initial defect is used to describe the severity of the weld defect. Fatigue life prediction is achieved based on equivalent fracture parameters and high‐stress fatigue life reference points fitted to obtain a P‐S‐N curve for the entire stress range. Taking the 6082‐aluminum alloy T‐welded joints as the object, the test data under tensile load P‐S‐N curve fitting and crack growth simulation were carried out to compare and verify the applicability under constant and equivalent spectral load. This method enables deterministic fatigue life prediction with less testing and cost. Meanwhile, the approach incorporates the uncertainty of the physical model of the weld into the P‐S‐N curve, simplifying the process of calculating the probabilistic fatigue life.

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“…Therefore, weld crack detection is an essential step in the production process and holds great significance for the reliability of metal connections. [1][2][3][4] Eddy Current Infrared Thermography is an effective visual non-destructive testing technique that combines electromagnetic induction heating with infrared thermography. Compared to traditional defect detection methods, infrared thermography offers the advantages of non-contact, fast detection speed, and graphical display of results, while the electromagnetic induction heating offers the advantages of fast, efficient and localized heating.…”

Section: Introductionmentioning

confidence: 99%