Advanced NDE Technologies for Quality ControlNovember 9th, 2012

Dr. Jeong NaTechnology LeaderNDE Group1250 Arthur E. Adams DriveColumbus, OH 43221

Advacned NDE Technologies

Matrix Phased Array (MPA) Ultrasonics

Laser Based Ultrasonics Array Eddy Current Ultrasonically Induced Thermography

Linear Phased Array UT One-Dimensional Array Configuration Line Focusing, Steering and Electronic Scanning

Focusing Steering Scanning

PiezoElements

Matrix Phased Array (MPA) Technology Provides 2-Dimensional Electronic Control of Beam:

Focusing, Steering, and Scanning

Each bar represents firing delay for each element

3-D MPA Probe Convex Surface Contour No Requirement of Steering Less Number of Elements (8x8) Lower Frequency (12 MHz)

Automotive Resistance Spot Welds Provides 2-D Image of Weld Nugget along with

Diameter and Area Information

6 mm RSW

ScreenShot

Probability of Detection (POD) Nugget Size Ranged between 4 - 6 mm for Two 0.7 mm Sheets One Hundred Weld Samples Approximately 98% Accuracy in Sizing

Weld Nugget Diameter(0.7 mm Thickness)

0.0

2.0

4.0

6.0

8.0

10.0

0.0 2.0 4.0 6.0 8.0 10.0

Avg. Peel/Chisel Destructive Test Dia. (mm)

Avg.

UT

Dia

. (m

m)

UT vs Destructive

Ideal

95% LUS

Laser Based Ultrasonics

• Non-contact• Fast Scan• Complex Geometries• Hostile Environments• High Spatial Resolution

• Versatile – Very small to Very Large Parts

1. Laser Generation2. Laser Detection3. Hardware, electronics, computers

Elastic Waves

VL > VS > VRSound Velocity:

Weld Joint Inspection

Levesque et.al. “Defect Detection and Residual Stress Measurement in Friction Stir Welds using Laser Ultrasonics”, LU 2008.

Butt Joint

Decreasing lack of penetration along weld

Weld Joint

Mechanical Properties

Blouin et. al. “Detection of Skin Disbond in Honeycombs and Coating Detachment by Laser Tapping Technique”, LU 2008.

Honeycomb delamination and disbond

Fundamentals of Eddy Current

Metallic Specimen

Drive Coil

EddyCurrent

Magnetic Flux Lines

.Metallic Specimen

Drive Coil

EddyCurrent

Magnetic Flux Lines

.

Crack

No Flaw With Flaw

Array Eddy Current Technology

Spot A Spot B

32 Element Array Probe

Scanner

Example - FSW Inspection

FSW

Friction Stir Welded Aluminum Plate (1” thick) 32 Element Flexible Eddy Current Probe (Multi

Frequency)

Scan Direction

Inspection Results

20 kHz 480 kHz

Ultrasonically Induced Thermography

UltrasonicHorn Temperature

MeasuringDevice

(IR or Optical)TestSpecimen

AcousticEnergy

• Fast and Non-Contact Inspection• Easy to Interpret Inspection Results

Ultrasonic Induced Thermography

Through Transmission Measurement Single Side Measurement

Ultrasonic Horn

Temperature Sensor

Example (Resistance Spot Welded Thin Metal Plates)

Good WeldBad Weld

X-ray image showing weld nuggets(2 mm diameter RSW)

0

1

2

3

4

5

0 5000 1 104 1.5 104

Good WeldBad Weld

Cha

nge

in T

empe

ratu

re (o C

)

Time (ms)

Correlation to Pull Strength

Summary

Wide range of inspection applications with matrix phased array technology with accuracy and reliability

Laser based ultrasonics is getting widely used across the board as a fast non-contact inspection tool

Imaging capability of array eddy current can reduce operator dependency with easy to understand inspection results

Non-contact ultrasonically induced thermography technique makes it possible to develop a high speed automated inspection system for weld quality as well as bond quality