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With the ongoing development of materials and manufacturing techniques, new product design opportunities manifest themselves. However, care must be taken when applying techniques and material where there is less inherent knowledge about different parameters’ effect on the integrity of the final component. In conjunction with destructive testing of components, non-destructive evaluation (NDE) provides valuable insight into the manufacturing process reliability, as well as the possibility for subsequent future in-service inspection. Phased array ultrasonic testing (PAUT) facilitates the inspection of complex geometries on a wide set of material. Mathematical modelling of ultrasonic signal facilitates the optimization of inspection procedures by e.g., maximizing the probability of detection (POD) of specific defect types. In this paper, the response from an immersion annular phased array probe is experimentally validated to the output of the simulation software simSUNDT. In order to only validate the probe model (as both transmitter and receiver) a set of well-defined defects are used. The validity of the simulated amplitude response from side-drilled holes at a depth range of 20-115 mm is investigated. A total of 14 SDH holes in one test piece of is used as cases for validation. The results show a good correspondence between simulated and experimental data for the case where the probe is normal to the component surface., CC BY 4.0

The total focusing method (TFM) is a post-processing imaging technique applied on full matrix capture (FMC) ultrasonic inspection (UT) dataset. In TFM the ultrasonic wave energy is synthetically focused on every pixel in the image region of interest (ROI). In terms of half-skip TFM (HSTFM), wave mode conversion happens when the wave rebounds at interface, such as specimen backwall. This paper aims to propose and evaluate a method that involves Snell’s law to address accurate estimation of distanceof-flight (DOF) of wave propagation when wave mode conversion appears in HSTFM. This HSTFM algorithm is applied to both experimental and simulated FMC dataset that inspects a surface-breaking notch for notch image reconstruction. Comparisons between images with and without considering Snell’s law in wave mode conversion show visible difference that could lead to misinterpretations in characterizing the defect. The sensitivity of TFM to varying defect features such as defect tilt angle is also studied using simulated FMC datasets., CC-BY 4.0

Lightweight and optimized designs through modern metal additivemanufacturing (AM) require reliable manufacturing processes and put highdemands on quality assessment and control. This part addressesnondestructive testing (NDT) technologies and their industrial AMapplications with a focus on process monitoring, control, and development.Data derived from NDT can be used for process monitoring (as sensors), inprocess nondestructive evaluation (NDE), or postprocess NDE. This chapteraims to define and point out the distinction between these differentframeworks. The methods and techniques addressed include (a) Defectsintroduced during manufacturing, welding (pores, lack of fusion, etc.) withthe NDT perspective in focus; (b) in-service inspection (ISI) andmanufacturing control (in-process and postprocess NDE); (c) NDT methodsand associated physics; (d) standards related to NDT for AM, includingprobability of detection (POD); and (e) mathematical modeling andapplication of NDE simulations.

To reduce costs of production and increase economic sustainability it is necessary to introduce quality assessment in an early stage in the manufacturing process. In an ongoing European project (Product Uniformity Control – PUC), the intention is to use ultrasonic information to assess microstructure parameters that are related to macroscale qualities such as mechanical properties. Laser induced ultrasonic technique (LUS) requires no media and can generate and detect ultrasonic information at some distance from the component. This technique is therefore addressed within this project as a solution to measure ultrasonic properties in an industrial environment. Mathematical modelling of the ultrasonic wave propagation problem has been used in order to get a deeper understanding of the physics and to identify ultrasonic properties that can be used as an indirect measurement of grain size. The use of both analytical and numerical models enabled extensive parametric studies together with investigation of ultrasonic interactions with well-defined individual microstructures. The LUS technique has previously been applied to e.g. monitor grain growth during thermomechanical processing of metals. These applications identified and used a correlation with the frequency content of the attenuation. This have been investigated as a possible indirect measurement of grain size, also in this project. The models have been used to verify the correlations and to evaluate different procedures that could be applied as an industrial solution. The suggested procedure is based on deconvolving two successive echoes and has been experimentally validated by two different LUS systems. The reference samples used in the validation were produced by changing the annealing temperature and time to obtain a variation in grain sizes. These grain sizes were then identified by EBSD and the samples were examined in terms of grain size influence on spectral attenuation., QC 20190213

A European consortium consisting of four major steel manufacturers and ten academic technology institutes has conducted a research and development project, called “Product Uniformity Control“ (PUC) in the period 2013 to 2017. This project aimed to develop and improve non-destructive (inline) measurement techniques to characterise the (uniformity of the) microstructure of steel strip products. In this project, a multitude of strip steel samples from various stages of production have been collected from the four participating steel manufacturers. The samples have been characterised in various ways, namely on their (1) non-destructive measurement parameters using different techniques suited for inline evaluation, (2) fundamental ultrasonic and electromagnetic properties (wave speed, ultrasonic attenuation, magnetisation loops, coercive field), (3) tensile properties (stress-strain curves) and (4) microstructure (by optical micrographs and EBSD images). The correlations between these different characterisations will be addressed. Besides the experimental characterisation, a strong accent has been on modelling activities: during the project, fundamental models have been developed to describe, starting from 2D and 3D microstructures, the ultrasonic and magnetic properties, which are next used as input to sensor models that predict the output of the inline measurement systems. This contribution presents the recent results of experimental work, which underlines the importance of associated modelling studies for the interpretation of the measurement data for the benefit of inline characterisation of the mechanical properties complementary to traditional destructive tensile testing., QC 20231030

QC 20180611