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Robotic sensing is used in many sectors to improve the inspection of large and/or complex parts, enhancing data acquisition speed, part coverage and inspection reliability. Several automated or semi-automated solutions have been proposed to enable the automated deployment of specific types of sensors. The trajectory to be followed by a robotic manipulator is typically obtained through the offline programmed tool paths for the inspection of a part. This method is acceptable for a part with known geometry in a well-structured and controlled environment. The part undergoing assessment needs to be precisely registered with respect to the robot reference system. It implies the need for a setup preparation phase for each new part, which can be very laborious and reliant on the human experience. This work combines real-time robot control and live sensor data to confer full autonomy to robotic sensing applications. It presents a novel framework that enables fully autonomous single-pass geometric and volumetric inspection of complex parts using one single robotised sensor. A practical and robust robot control sequence allows the autonomous correction of the sensor orientation and position to maximise the sensor signal amplitude. It is accompanied by an autonomous in-process path planning method, capable of keeping the inspection resolution uniform throughout the full extension of the free-form parts. Last but not least, a by-product of the framework is the progressive construction of the digital model of the part surface throughout the inspection process. The introduced framework is scalable and applicable to widely different fields.

Nondestructive testing methods used for the testing of rail in tracks worldwide can be limited by discontinuity location or orientation within the rail. Vertical split head and rail base cracks are among those types of discontinuities that are difficult to detect, which in some cases may result in a reail failure in service. A noncontact and remote hybrid ultrasonic technique has been developed by combining laser generation with air coupled detection of ultrasonic signals in rails. The test apparatus mounts on a railroad pushcart and tests are performed in motion with all components kept above the running surface of the rail track. Tracks have been tested for vertical split head and rail base cracks with high success in detection.

The capabilities of most non-destructive testing methods have been combined with some degree of automation in recent years, to enhance data acquisition speed, part coverage and inspection reliability. A plethora of automated or semi-automated inspection systems have been engineered to enable the robotic manipulation of specific types of sensors. Robotic inspection systems are usually operated through off-line programmed tool-paths. This approach works well when an accurate model of the part is available and the robotic inspection takes place in a well-structured environment, where the part position is precisely registered with respect to the robot reference system. However, it makes the inspection setup for each new part very time-consuming and dependent on the skills and experience of the robot programmer. Moreover, the real geometry of a part may significantly deviate from its digital counterpart, resulting in inaccurate tool paths. This work introduces a new approach capable of conferring full autonomy to robotic sensing applications, providing a breakthrough in the stateof-the-art. As a result of this work, fully autonomous single-pass geometric and volumetric inspection of complex parts, using one single robotized sensor, becomes possible. This concept can find wide applicability to the open problems of structural health monitoring of the modern age.

The spine is the load-bearing structure of human beings and may present several disorders, with low back pain the most frequent problem during human life. Signs of a spine disorder or disease vary depending on the location and type of the spine condition. Therefore, we aim to develop a probabilistic atlas of the lumbar spine segment using statistical shape modeling (SSM) and then explore the variability of spine geometry using principal component analysis (PCA). Using computed tomography (CT), the human spine was reconstructed for 24 patients with spine disorders and then the mean shape was deformed upon specific boundaries (e.g., by ±3 or ±1.5 standard deviation). Results demonstrated that principal shape modes are associated with specific morphological features of the spine segment such as Cobb’s angle, lordosis degree, spine width and height. The lumbar spine atlas here developed has evinced the potential of SSM to investigate the association between shape and morphological parameters, with the goal of developing new treatments for the management of patients with spine disorders.

Ultrasonic testing has been used for material analysis and inspection since 1930's. Nevertheless, the applicability of ultrasonic waves to new complex cases is still growing, thanks to the availability of powerful electronics and software. However, the complication that slows down the deployment of ultrasonic inspection to geometric complex parts and structures arises from the wave refraction phenomenon. A clear understanding of the ultrasound wave propagation, impacted by refractions, is crucial to interpret the data obtained from the inspection of multi-layered/multi-medium test subjects as it is not always possible to assume that mechanical waves travel in straight lines. This work presents suitable approaches for solving the ray-tracing problem in multi-layered structures. Accurate benchmarking shows that the use of the Newton-Raphson root-finding method allows a threefold reduction of the computation time, when compared to the bisection-based root-finding methods. An effective combination of the Newton-Raphson methods with bisection-type iterations is also proposed and discussed. Although the work repeatedly refers to the field of ultrasonic inspection, the presented findings are relevant and applicable to areas beyond material inspection.

Many industrial sectors face increasing production demands and need to reduce costs, without compromising the quality. Whereas mass production relies on well-established protocols, small production facilities with small lot sizes struggle to update their highly changeable production at reasonable costs. The use of robotics and automation has grown significantly in recent years, but extremely versatile robotic manipulators are still not commonly used in small factories. Beside of the investments required to enable efficient and profitable use of robot technology, the efforts needed to program robots are only economically viable in case of large lot sizes. Generating robot programs for specific manufacturing tasks still relies on programming trajectory waypoints by hand. The use of virtual simulation software and the availability of the specimen digital models can facilitate robot programming. Nevertheless, in many cases, the virtual models are not available or there are unavoidable differences between virtual and real setups, leading to inaccurate robot programs and time-consuming manual corrections. This could be avoided by measuring the real-geometry and the position of the specimen, which creates the paradox of having to plan robot paths for surface mapping purposes, before the originally intended robot task can be approached. Previous works have demonstrated the use of robotically manipulated optical sensors to map the geometry of samples. However, the use of simple user-defined robot paths, which are not optimized to the part geometry, typically causes some areas of the samples to not be mapped with the required level of accuracy or to not be sampled at all by the optical sensor. This work presents an autonomous framework to enable adaptive surface mapping, without any previous knowledge of the part geometry being transferred to the system. The article gives an overview of the related work in the field, a detailed description of the proposed framework and a proof of its functionality through both simulated and experimental evidences.

BACKGROUND: Incisional hernia is one of the most common complications after abdominal surgery with an incidence rate of 11 to 20% post laparotomy. Many different factors can be considered as risk factors of incisional hernia recurrence. The aim of this study is to confirm and to validate the incisional hernia recurrence risk factors and to identify and to validate new ones. METHODS: In the period from July 2007 to July 2017, 154 patients were selected and subjected to incisional hernia repair. The surgical operations were conducted under general anaesthesia. Patients received antibiotic prophylaxis when indicated, according to the hospital prophylaxis scheme. Inclusion criteria of the study were single operator case studies and open laparotomy for incisional hernia repair. The statistical analysis proposed to identify and to verify the risk factors for recurrence of incisional hernia is the Support Vector Machine (SVM). The analysis was conducted verifying 34 risk factors. RESULTS: The data analysis confirmed the known correlations showed in the international literature with a greater incidence of comorbidities such as diabetes 37%, dyslipidaemia and hypercholesterolemia with a cumulative incidence of 16%; tobacco smoke - by combining categories smokers and ex-smokers - reach 46%, COPD 16% and hypertension 51%. CONCLUSIONS: The analysis of the data therefore confirmed the correlations showed in the international literature. A KSVM-based system to classify incisional hernia recurrence has been presented. The type of prosthesis and the site of its implant also play a significant role in the development of the recurrence. Sensitivity (86,25%), Specificity (87,14%), Negative Predictive Value (84,72%), Precision (88,46%), Accuracy (86,67%), and Error (13,33%) scores obtained using the proposed technique highlight the validity for the relapse's classification methodology.

This work describes a numerical study on non-destructive evaluation of interlayer disbond defects in aerospace grade Fibre Metal Laminate sheets (FMLs). A recently proposed infrared non-destructive testing setup is considered, where a continuous laser is moved over the material surface, while the thermal footprint of the moving heat source is acquired, e.g. by an infrared thermal camera. Interlayer disbonds are then detected by analysing the features of the acquired thermograms. The experimental feasibility of this approach has been recently proved. The present work proposes a numerical simulation of the NDT approach, where the material thermal response is analysed and correlated to defects signatures. The numerical study has in particular investigated the influence of a number of different features on the defect detectability, and on the accuracy of defect edges and position identification. Such features comprise different FML materials (GLARE, CARAL, Ti-Gr), laser heat deposition and regions of data analyses.

Fibre Metal Laminates (FMLs) describe a number of aerospace-grade layered structural materials where thin metal alloy foils are interleaved with Fibre Reinforced Polymer (FRP) plies. Such material hybridisation at the layer meso-scale poses a challenge for non-destructive testing (NDT). On the other hand, the need for NDT inspection of FMLs arises due to the potential development of interlayers disbonds, both during fabrication or in-service. This work describes the successful implementation of two Infrared-NDT approaches to evaluate a defected FML panel made of Titanium/Graphite (Ti-Gr). One technique is based on the modulation of the deployed heat from a low-cost halogen lamp, to retrieve defects as phase-contrast signatures from harmonics in the frequency domain. The second technique uses a flying laser heat-source, raster scanning the surface, searching for defect signatures on the heat distribution trail of the moving laser. The work explores also the opportunity to collimate the laser heat source as a round spot or a linear distribution. The proposed non-conventional IR-NDT approaches are also compared with a well-established Pulsed Phase Thermography (PPT) algorithm, demonstrating a similar ability of defects evaluation, but offering some favourable features, which are highlighted in the work.

Additive manufacturing has been recently employed in industrial sectors with the fundamental requirement for zero defect parts. Technological developments in additive manufacturing notwithstanding, there continues to be a scarcity of non-destructive inspection techniques to be exploited during the manufacturing process itself, thus limiting industrial advancements and extensive applications. Therefore, being able to integrate the defect inspection phase within the additive manufacturing process would open the way to enabling corrective actions on the component in itinere, that is, before reaching the final product. For this reason, new methods of in-process monitoring are gaining more and more attention nowadays. In this work, a remote laser thermographic methodology is employed as a mean to detect micrometric defects in additive manufactured samples. Beforehand, a preliminary Finite Element Analysis was carried out in order to optimize the sensitivity of the technique to the micrometric defects. Our results indicate that the technique is proved to be quite successful in detecting flaws, with the added plus of being suitable for integration in the additive manufacturing equipment, thus allowing a continuous in-line inspection.

Definition of size, shape and location of defects into a mechanical component is of extreme importance in the manufacturing industry in general and particularly in high-tech applications, and in applications that can become dangerous due to the structural failure of mechanical components. In this paper, a laser-UT system has been used to define position and shape of internal defects in aluminum plates. An infrared pulsed laser is used to generate ultrasonic waves in a point of the plate and a CW laser interferometer is used as receiver to acquire the out-of-plane displacements due to the ultrasonic waves in another point of the plate. The method consists of acquiring a B-Scan map on which some information on the defects in the mechanical component are visible. Storing the characteristics of the wave reflected by the defect and acquired in the B-Scan, the detection and the drawing of the defect is possible. The acquisition of the times of arrival of the waves reflected by the defect from the B-scan allows defining large parts of the shape of the defect. The times of arrival are acquired from the B-scan by analyzing the colour variations due to the wave reflected by the defect. The experiments operated from both sides of the plate allow drawing the defect in a virtual image of the plate section, from which the definition of defect shape and position can be determined.

The present work investigates the features of an active Infrared-NDT Thermography technique derived from a Flying Laser Spot set-up for the analysis of interlaminar disbonds in layered structures in general and Fibre Metal Laminates in particular. The presented technique uses a laser-spot heat source, which moves at a constant speed, raster scanning the object surface. Interlaminar defects parallel to the surfaces act as barriers towards through-the-thickness heat diffusion. This produces some modifications over the surface thermal field which are well identified in the Standard Deviation calculated over a Reference Area following the heat source. The mechanisms leading to such defect signature are investigated in this work by means of Finite Element Analyses which model the dynamic thermal problem on a GLARE sample with triangular disbond defects at inner interfaces. An extended number of parameters is changed to study their influence on the defect signature, and the FEA analysis is also compared to an analytical and an experimental case studies for further validation.

Pressure vessels operating in sour service conditions in refinery environments can be subject to the risk of H₂S cracking resulting from the hydrogen entering into the material. This risk, which is related to the specific working conditions and to the quality of the steel used, shall be properly managed in order to maintain the highest safety at a cost-effective level. Nowadays the typical management strategy is based on a risk based inspection (RBI) evaluation to define the inspection plan used in conjunction with a fitness for service (FFS) approach in defining if the vessel, although presenting dangerous defects such as cracks, can still be considered “fit for purpose” for a given time window based on specific fracture mechanics analysis. These vessels are periodically subject to non-destructive evaluation, typically ultrasonic testing. Phased Array (PA) ultrasonic is the latest technology more and more used for this type of application. This paper presents the design and development of an optimized Phased Array ultrasonic inspection technique for the detection and sizing of hydrogen induced cracking (HIC) type flaws used as reference for comparison. Materials used, containing natural operational defects, were inspected in “as-service” conditions. Samples have then been inspected by means of a “full matrix capture” (FMC) acquisition process followed by “total focusing method” (TFM) data post processing. FCM-TFM data have been further post-processed and then used to create a 3D geometrical reconstruction of the volume inspected. Results obtained show the significant improvement that FMC/TFM has over traditional PA inspection techniques both in terms of sensitivity and resolution for this specific type of defect. Moreover, since the FMC allows for the complete time domain signal to be captured from every element of a linear array probe, the full set of data is available for post-processing. Finally, the possibility to reconstruct the geometry of the component from the scans, including the defects present in its volume, represents the ideal solution for a reliable data transferring process to the engineering function for the subsequent FFS analysis.

The non-destructive evaluation of defects by automatic procedures is of great importance for structural components. Thanks to the developments of the non-contact ultrasonic techniques, the automation of the inspections is gaining a progressively important role. In this work, an automatic inspection technique for the evaluation of defects by the analysis of B-scan images obtained by a laser ultrasonic system is presented. The data are extracted directly from a B-scan map obtained for a panel with internal defects, and are used to build an image of the cross section of the panel. The proposed automatic procedure allows the definition of size, position and shape of defects in panels of known thickness.

Offshore pipelines construction is a technological challenge. Increasing water depth, harsh environments, engineering and commercial constraints are just some of the existing issues. Material selection therefore plays a key role and, for several applications, seamless pipes offer both the best technical and commercial compromise. Typically, NDT inspection of girth welds is carried out using the phased array based automated ultrasonic testing (AUT) zonal discrimination approach. AUT, compared to other techniques, guarantees a higher probability of detection of flaws and it also allows a really accurate assessment of the indications. However, since one of the peculiarities of this technique is that it uses focused beams, it is strictly linked to the geometry of the joint. According to the most credited international codes [1], performing AUT the allowable wall thickness (WT) variation from the nominal one is ±1.5 mm (or less for higher strain applications). Seamless pipes are likely to exceed this limit, particularly taking into account that the WT commonly varies point by point around the circumference. For this reason, several approaches have been developed during the years from AUT contractors such as using dedicated techniques (e.g. multi-shooting) or using multiple calibration blocks. However, all these solutions may deeply influence costs because of the additional qualification tests required and the potential impact on the cycle time. Starting from AUT validation data to build the model and using simulation software as tool, this study analyses the influence of WT variation on the reliability and accuracy of zonal discrimination approach. Real flaws geometry has been extrapolated from macro-sectioning. Actual focal laws settings have been considered. After validating the proposed model by comparing the simulation results with actual ones, several steps of base material WT variation are considered in order to understand the effect on the ultrasonic response of the flaws in object.

Friction stir welding (FSW) is an innovative process that has been successfully used in joining aluminum alloys, normally difficult to weld. Important advantages over fusion welding are better retention of baseline material properties, lower residual stresses and excellent mechanical properties. Defects that occur in FSW joints are due to improper tooling or setup. Non-destructive techniques used to inspect FSW joints are X-rays, eddy current, conventional ultrasonic testing and dye penetrant proper only for surface breaking defects. Currently there is no non-destructive technique that can guarantee absence of flaws in friction welds during manufacturing. In this work, non-destructive remote testing of friction welds, based on laser ultrasonic technique, was investigated to detect and quantify defects in the joint. The laser ultrasonic system generates ultrasonic acoustic waves by thermal expansion and detects the surface vibration by an interferometric receiver. Several specific FSW samples were inspected; some, manufactured with optimum parameters, used as calibration samples, and others, manufactured with modified settings, with defects. The results of the tests conducted on the FSW samples show that the system is able to detect the defect. A quantitative analysis of the defects was extrapolated from the ultrasonic signals acquired across the weld. Since the defect evaluation can be done in-line, during the friction weld manufacturing process, the laser ultrasonic technique plays an important role in containing the FSW production cost.

Train loads and travel speeds have increased over time, requiring more efficient non-destructive inspection methods. Railway axles are critical elements; despite being designed to last more than 20 years several cases of premature failure have been recorded. Train axles are inspected regularly, but the limits associated to the traditional inspection technologies create a growing interest towards new solutions. Here a novel non-destructive inspection method of in-service axles based on non-contact data collection is presented. The propagation of surface waves, generated by a thermo-elastic laser source, is investigated using a finite element method based on dynamic explicit integration. Coupled thermo-mechanical simulations allow visualization of the ultrasonic field guiding the definition of the optimal NDT setup. The geometry of the axle and of the elements mounted on it is accurately reproduced; moreover the press fit effect caused by the wheel and the bearing rings is implemented. The current NDT techniques for railway axles require removing wheels and other components from the axle. The presented scheme uses non-contact ultrasonic generation and detection allowing non-contact in-service inspection of railway axles at trackside station. The numerical results are promising and encourage us to test the new approach experimentally.

I controlli non distruttivi basati sull’impiego di ultrasuoni sono ampiamente usati per la loro efficacia e affidabilità nel rilevamento di difetti. La generazione di onde ultrasonore e la propagazione in strutture di forma non regolare sono difficili da analizzare, soprattutto se la sorgente impiegata è un laser. Le tecniche numeriche per la simulazione del fenomeno reperibili in letteratura mostrano limiti di applicabilità per frequenze nel campo dei MHz e lunghezze d’onda molto corte. In questo lavoro presentiamo un metodo numerico in grado di risolvere accuratamente ed efficientemente problemi di generazione di onde ultrasonore tramite laser, con frequenze nel range dei MHz, e di propagazione in corpi relativamente estesi. La ricezione viene simulata con la propagazione degli ultrasuoni in aria, al fine di poter ottimizzare la configurazione completa per controlli non distruttivi con ultrasuoni senza contatto. Diverse configurazioni di ispezione sono state prima simulate tramite l’analisi numerica e poi riprodotte sperimentalmente per confrontare i risultati. Non-destructive testings (NDT) based on ultrasonic methods are extensively used for their effectiveness and reliability in detecting defects. The generation of ultrasonic waves and propagation in non-regular geometries are difficult to analyze, especially if the source used is a laser. Numerical techniques to simulate the phenomenon found in literature have proved to be limited in their applicability by the frequencies in the MHz range and very short wavelengths. In this paper we present a numerical method to accurately and efficiently solve problems of laser-generated ultrasounds, with frequencies in the MHz range, and propagation in relatively large bodies. Detection is simulated with the propagation of ultrasounds in air, to optimize the complete configuration for non-contact ultrasonic NDT. Different configurations of inspections have been first simulated using numerical analysis and then reproduced experimentally to compare the results.

A computationally-effective approach for calculating the electromechanical behavior of SWNTs and MWNTs of the dimensions used in nano-electronic devices has been developed. It is a mixed finite element-tight-binding code carefully designed to realize significant time saving in calculating deformation-induced changes in electrical transport properties of the nanotubes. The effect of the MWNT diameter and chirality on the conductance after mechanical deformation was investigated. In case of torsional deformation results revealed the conductance of MWNTs to depend strongly on the diameter, since bigger MWNTs reach much earlier the buckling load under torsion their electrical conductivity changes more easily than in small diameter ones. For the same outer diameter, zig-zag MWNTs are more sensible to twisting with respect to armchair MWNTs since the hexagonal cells are oriented in such a way that they oppose less resistance to the buckling deformations due to torsion. Thus small diameter armchair MWNTs should work better if used as conductor, while big diameter zig-zag MWNTs are more indicated for building sensors.

The aim of this work is the analysis of the contact area in a knee prosthesis using two different approaches. In particular, the interface between the femoral component and the polyethylene insert has been studied both numerically and experimentally. The interest in studying the contact area is related to the fact that the wear of the polyethylene insert, due to the high contact pressures, represents one of the major causes of failure of the total knee prosthesis. The possibility to evaluate the contact area at different loads and mutual position between femur and tibia is, therefore, of fundamental importance to study the service life of a prosthesis and to improve its performance. The finite element numerical approach has required the acquisition, through reverse engineering, and CAD modelling of the prosthetic components. Then the FEM simulations have been developed considering two different load conditions. In order to compare the calculated data, the same load configurations have been used for experimental tests based on ultrasonic method. In this case, some preliminary tests were required to calibrate the system depending on the particular characteristics of materials, geometries and surface finish of the prosthesis. The results show a good correlation between the data obtained with the two different approaches and, consequently, a good level of reliability of the procedures developed for the numerical and experimental evaluation of the contact area. The numerical procedure can be used to determine the area for different angles and loads, but especially in the design phase. The ultrasonic technique can be used to validate the numerical data.