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transcript
Advanced ManufacturingNon-Destructive Testing &
By: Hamed Malekmohammadi (Ph.D.)05.June.2020 NDTonAIR 8th (Last) Training Event
Outline
➢ Introduction to NDT and Quality Control
➢ Classification of NDT Methods
➢ Conventional, advanced and automated NDT
➢ Automated NDT
➢ Applications
➢ How advanced NDT saves cost and time?
➢ Bigger vision: from NDT to total asset management
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Part One
Quality Control and NDT
• Quality Control (QC): an aggregate of activities (such asdesign analysis and inspection for defects) designed toensure adequate quality especially in manufactured products(Merriam-Webster.com)
• Non-Destructive Testing (NDT): the process of inspecting, testing, or evaluating materials, components or assemblies for discontinuities, or differences in characteristics without destroying the serviceability of the part or system (ASNT.org)
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NDT Methods’ basic Classification (ASNT.com)
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Liquid Penetrant (PT)
Magnetic Particle (MT)
Radiography (RT)
Ultrasonic (UT)
Electromagnetic (ET)
Visual (VT)
Pri
mar
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eth
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Guided Wave (GW)
Acoustic Emission (AE)
Laser Methods (LM)
Leak Testing (LT)
Magnetic Flux Leakage (MFL)
Neutron Radiography (NR)
Infrared Thermography (IR)
Vibration Analysis (VA)
Seco
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Met
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NDT Methods’ deep Classification
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Radiography (RT)
Ultrasonic (UT)
Visual (VT)
Vo
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etri
c
Guided Wave (GW)
Acoustic Emission (AE)
Laser Methods (LM)
Leak Testing (LT)
Magnetic Flux Leakage (MFL)
Neutron Radiography (NR)
Infrared Thermography (IR)
Vibration Analysis (VA)
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Phased Array (PA)
TOFD
Immersion
Pulse-Echo
Through-Transm.
Conventional NDT
Automated UT
Advanced NDT
Liquid Penetrant (PT)
Magnetic Particle (MT)
Electromagnetic (ET)
NDT Methods’ deep Classification
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Liquid Penetrant (PT)
Magnetic Particle (MT)
Radiography (RT)
Ultrasonic (UT)
Electromagnetic (ET)
Visual (VT)
Vo
lum
etri
c
Guided Wave (GW)
Acoustic Emission (AE)
Laser Methods (LM)
Leak Testing (LT)
Magnetic Flux Leakage (MFL)
Neutron Radiography (NR)
Infrared Thermography (IR)
Vibration Analysis (VA)
Surf
ace
/Ne
ar S
urf
ace
CT
Computed RT
Analogue RT
Digital RT
Conventional NDTAdvanced NDT
NDT Methods’ deep Classification
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Liquid Penetrant (PT)
Magnetic Particle (MT)
Radiography (RT)
Ultrasonic (UT)
Electromagnetic (ET)
Visual (VT)
Vo
lum
etri
c
Guided Wave (GW)
Acoustic Emission (AE)
Laser Methods (LM)
Leak Testing (LT)
Magnetic Flux Leakage (MFL)
Neutron Radiography (NR)
Infrared Thermography (IR)
Vibration Analysis (VA)
Surf
ace
/Ne
ar S
urf
ace
MW & THz
RFT
Eddy Current
ACFM
Conventional NDTAdvanced NDT
Conventional, Advanced and Automated NDT
• Conventional: basic NDT techniques havebeen in use as analog and now as digital,but they are conceptual methods of NDT,e.g. PT or RT
• Advanced: most recent developments in NDT techniques based on the concepts of conventional methods or are newly developed and independent, e.g. PA or IRT
• Automated: any of conventional or advanced NDT techniques, which have been automated (mechanized) by means of robotic or automation systems
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Automated NDT
• Automated NDT is a growing but matured approach in NDT• Decreases the time and costs• Increases the accuracy and speed• Interpretation can be done automatically• Less dependent on operator errors and skills• Suitable for production lines and continuous NDT tasks
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• Can be implemented for maintenancetasks as well
• Can consist of one or more NDT techniques
www.Google.com
NDT Applications
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NDT
Aerospace Oil and Gas Automotive InfrastructurePower
GenerationManufacturing
Iron and Steel
Shipbuilding
Pipe and Tube
Engine parts
Airframe
Composites
Maintenance
Pipelines
Storage Tanks
Pressure Equ.
LNG
Plants
Engine parts
Body and chassis
Composites
Bridges & Tunnels
Railway
Airport
Military and defense
Solar
Wind
Nuclear
Fossil fuel
Water
NDT Applications → Oil and Gas → 1st Case: Pipelines
• Every year thousands of km of pipelines
• Huge investment, money and time
• Costs: Engineering, Procurement, Construction
• Construction cost: mob-demob, personnel, logistics
• On- or off-shore: NDT in night shift →
• Goal: Down-time in installation shall be minimized
• Can improve other parts but NDT is 50% of time
• Offshore: no day/night shift but still significant time for NDT
• Main conventional NDT: RT, manual UT
• Radiation hazard, test time is long
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NDT Applications → Oil and Gas → 2nd Case: LNG tanks
• Construction problems are similar to pipelines• Construction time and costs are higher• Several NDT methods have to be used simultaneously• Down/waiting time due to NDT is high• LNG storage tanks:▪ Operating temperature: -163◦C▪ Materials:✓ Base metal:
9% Ni Steel (ASTM A553)✓ Welds:
Inconel and Hastelloy (Austenitic)• Austenitic welds →• Dissimilar grain structure• Difficult to test with both RT and UT
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NDT Applications → Oil and Gas → 2nd Case: LNG tanks
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Weld
Base
NDT Applications → Oil and Gas → What we are looking for?
• Typical weld defects
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NDT Applications → Oil and Gas → What are the solutions?
• Various advanced NDT are in the market: AUT, DRT
1st Generation: multi-probe AUT system
3rd Generation: 2D matrix Phased Array probe
Brand-new automatic X-Ray scanner
© ApplusRTD, Netherlands
NDT Applications → Oil and Gas → AUT Concepts
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NDT Applications → Oil and Gas → DRT Concepts
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sensor
source
Beam travels through 2 walls but due to high magnification of first wall only the second wall is sharply visible on screen.
DWSI = Double Wall Single Image
sensorsource
SWSI = Single Wall Single Image
Beam travels through only 1 wall; hence this wall is sharply visible on screen.
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2” to 12” range 6” – 56” range
NDT Applications → Oil and Gas → DRT Concepts
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Active area
• Rayscan uses a digital sensor (like adigital photocamera... but for xrays)
• The x-ray photographs are 6mm wideand up to 220mm long
• 300 photographs (or frames) a second!• Software re-constructs all photographs
to a complete weld-image
NDT Applications → Oil and Gas → Conventional vs. Advanced
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NDT Applications → Oil and Gas → Conventional vs. Advanced
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Automated X-Ray (RayScan®)
NDT Applications → Oil and Gas → Conventional vs. Advanced
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Automated Ultrasonic (AUT for pipeline and tanks)
Bigger view → From NDT to asset management
• Structural Health Monitoring (SHM): diagnosis of thecurrent state of a structure, which consists of differentcomponents and materials. Structures undergo continuouschange caused by ageing processes, environmentalinfluences and also by unforeseen events e.g. earthquakes or(wind) buffeting
• Fitness for Service (FFS): is a best practice and standard usedby the oil & gas and chemical process industries for in-service equipment to determine its fitness forcontinued service
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Bigger view → From NDT to asset management
• Risk Based Inspection (RBI): Optimal maintenance processto examine equipment in industrial plants. It examinesthe Health, Safety and Environment (HSE) and business riskof ‘active’ and ‘potential’ Damage Mechanisms (DMs) toassess and rank failure probability and consequence. Thisranking is used to optimize inspection intervals based onsite-acceptable risk levels and operating limits, whilemitigating risks as appropriate. It can be qualitative,quantitative or semi-quantitative in nature
• Asset Integrity Management (AIM): The ability of an asset toperform its required function effectively and efficientlyproviding value through optimum return on capitalinvestment, whilst safeguarding life and the environment
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Bigger view → From NDT to asset management
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Operations PhaseConstruction Phase
Asset Integrity Management
Asset Integrity
Operate:to Design Intent
Design Maintain
Fabrication & Construction
Commission
Integrated Inspection Engineering and NDT&I
Bigger view → From NDT to asset management
⌂ Integrity management
→ Risk Based Inspection
→ Fitness for Service analysis
→ Degradation mechanism
→ Consequence of failure
→ Requirements, rules and regulations
→ NDT/SHM measurement locations
→ NDT/SHM method(s)
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Part Two
Outline
➢ Advanced manufacturing
➢ From Industry 1.0 to Industry 4.0
➢ Key advanced manufacturing techniques
➢ NDT in advanced manufacturing, NDT 1.0 to NDT 4.0
➢ Case study: Additive Manufacturing
➢ Challenges
➢ Summary and Prospect
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Part Two
Part Two
Advanced Manufacturing
• Manufacturing: act of converting raw materials to products bythe use of manual labour or machinery and that is usuallycarried out systematically with a division of labour. In a morelimited sense, manufacturing denotes the fabrication orassembly of components into finished products on a fairly largescale. (Britanica & Wikipedia)
• Advanced manufacturing: the use of innovative technologiesand methodologies for improved competitiveness in themanufacturing sectors →
▪ Quality controls▪ Lean production technologies▪ Supply chain integration▪ Advanced planning and scheduling
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Part Two
From Industry 1.0 to Industry 4.0
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Industry 1.0
• 18th century• Water- and steam-
powered machines• Mechanization
Industry 2.0
• 19th century• Electricity and assembly
line production• Mass production (Henry
Ford)
Industry 3.0
• 20th century (70’s)• Electronic devices, e.g.
transistor, integrated circuit chips
• Automation• PLC
Industry 4.0
• Information and communication technologies
• IOT• AR/VR
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Part Two
Advanced Manufacturing• Advanced Robotics and adaptive automation • Nano-technologies (materials and electronics)• Green and sustainable manufacturing (solar power, recycling)• Design and management of distributed supply chains (Cloud
computing for CAD/CAE/CAM)• Additive manufacturing (metals and plastics)• Composite manufacturing processes• Other processes:
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Process Example
Forming forging, rolling, extrusion, etc.
Moulding powder metallurgy, injection, etc.
Machining mill, lathe, etc.
Casting centrifugal, die, vacuum, etc.
Joining welding → LASER, ultrasonic, friction, etc.
Part Two
NDT and Advanced Manufacturing• Quality control a key feature in advanced manufacturing• To assure the quality →▪ Quality management system (e.g. ISO9001)▪ DT and NDT tools, inspection →✓ DT approach: sampling, offline✓ NDT approach: 100% control, online
Can be integrated to the manufacturing process
• Requirements →▪ Fast (real-time)▪ Reliable (stable and robust)▪ Automatic (no operator) ▪ Closed-loop (feedback to the manufacturing process)▪ Cost efficient▪ Comply with process
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Part Two
NDT 1.0 to NDT 4.0
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NDT 1.0
• Tools to enhance human senses
• Optical/visual mark• Impact (hammer)• Mic/stethocscope
NDT 2.0
• Electronics: devices• Surface to depth• Ultrasonics• X-ray, Gamma-ray• Magnetic
NDT 3.0
• Robotics• Automated NDT• Software tools• Image visualization• Computer algorithms
NDT 4.0
• Cloud-based• IOT• AR/VR• Wireless sensors• Sensor networks• Big data
NDT
Part Two
NDT 4.0 and Industry 4.0
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QualityProductivity
SafetySustainability
→In lifecycle of products
and assets
High precisionHarsh environments
DurabilitySmall size
Cost efficiency→
Guarantee the safe operation
Industry
4.0
Argumented RealityVirtual Reality
Embedded sensor systemsWireless/Network sensors
Cloud technology
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NDT 4.0 (Example)
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Part Two
Case Study: Additive Manufacturing (AM)• What is Additive manufacturing?▪ According to standard term (ASTM F2792), is defined as the
process of joining materials to make objects from 3D model data, usually layer upon layer, as opposed to subtractive manufacturing methodologies.
• What are AM applications?▪ Aerospace▪ Automotive▪ Healthcare▪ Product Development
• What are AM materials?▪ Thermoplastic▪ Metal▪ Ceramic▪ Biochemical
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Case Study: Additive Manufacturing → Processes
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Material extrusion
Directed Energy Deposition (DED)
Material extrusion
Material jetting
Binder jetting
Sheet lamination (LOM)
Vat polymerization
Powder Bed Fusion (PBF)
Direct Metal Laser Sintering (DMLS)
Selective Laser Sintering (SLS)
Selective Heat Sintering (SHS)
Electron Beam Melting (EBM)
Direct Metal Laser Melting (DMLM)
AM
Pro
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Case Study: Additive Manufacturing → How it works?
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Part Two
Case Study: Additive Manufacturing → Process Challenges *• Problems associated with AM processes:
1. Fast heating and cooling (~103–105 K/s) →▪ Suppressed phase transformations▪ Supersaturated phases▪ Segregation▪ Hot cracking▪ Thermal residual stresses
2. Unidirectional heat flow into substrate →▪ textured grains▪ anisotropic properties
3. Repeated heating and cooling cycles → temperatures can exceed Tα↔β → ▪ multiple phase transformations & complex microstructures▪ thermal residual stresses
* focused on metal-based AM
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Part Two
Case Study: Additive Manufacturing → Solutions
• Test and characterizations are necessary on- and off-line▪ Microscopy (e.g. SEM, TEM, EBSD, EELS)▪ Non-destructive Testing and Evaluations▪ Spectrometric techniques (e.g. GDOES)▪ Thermal techniques (e.g. DSC, DTA)▪ Hardness test (e.g. micro indentation)▪ Internal or surface attributes (eg. roughness)▪ Wear resistance▪ Fatigue, fracture and creep behavior
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Part Two
Case Study: Additive Manufacturing → Application of NDT
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In-situ
Off-line
Optical methods
X-Ray, XCT, ND,XBT
Infrared Thermography
Laser UltrasoundND
T in
AM
Ultrasound
EM techniques
High temp.
Complex Geometry
Part Two
Case Study: Additive Manufacturing → NDT Challenges
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AM Process
Decision making-
Feedback
In-situ NDTData
Acquisition
Post-processing
Big Data
Real-time processing
High speed
Material & process
Accuracy
Hazards
False calls
Part Two
NDT in Advanced manufacturing → Summary and prospect
• NDT is everywhere (onAIR, onART, underground, underwater, …)• Advanced manufacturing is growing fast and is finding
application in many areas of industry (e.g. AM, etc.)• There is a high demand for integration of QC/NDT solutions into
the production process• There are still challenges but new technologies will help• Advanced manufacturing and NDT can help promote each other
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Thanks for your attention!
Questions?
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And finally……
My sincere thanks goes to:
- Marco and Stefano for their unlimited support and
being a friend before being a colleague or supervisor;
- All ESRs; Abdoulaye, Akram, Bengisu, Houssem,
Jaishree, Khalid, Luca, Michael, Qiuji, Sergey, Sevilia,
Shaun, Silvio, Tommaso, Yongtak (Aadhik and Konrad)
for their valuable friendship and all I have learned from
them;
- All valued supervisors of NDTonAIR project for all they
taught us with passion and patience.