industrial –university of toronto collaboration in ... · 5/ a skilled new employee. 8 signal...

Industrial – University of Toronto Collaboration in Ultrasonic NDT

Tony SinclairMechanical & Industrial EngineeringUniversity of Toronto

[email protected]/labs/undel/

Outline

• Lab model for graduate student projects• Our industrial partners• Project Descriptions and results• Summary

2NDT in Canada 2015 Conference

University/Industry Project Model• Each student is assigned a project to solve a NDT problem for

an outside customer (manufacturer, research organization, Inspection company,...)

• U of T supervisor and industrial rep define scope of the project, milestones.

• Timeline ranges from 6 months up to 4 years

• The student splits work time between the university and industrial partner’s plant.

• Funding provided by federal granting agencies (NSERC, MITACS) plus support from the industrial partner.


Industrial Partners on Ultrasonic NDT• Alcan Aluminum• Advanced Measurement

and Analysis Group (AMAG)• ANDEC/CANDET• Atomic Energy of Canada• Canadian Nuclear Safety

Commission• DRDC Valcartier• Eclipse Scientific• Groupe Mequaltech• Hatch Limited• IRIS NDT

• National Aeronautical Assoc.• Nuclear Waste Management

Organization (NWMO)• Olympus NDT Canada• Ontario Power Generation• Pratt & Whitney Canada• Rockwell International• ShawCor Ltd.• Sigmabond Technolgies• Tessonics Inc.• Tower Automotive


Phased Array Inspection of Hot Specimens

• Industrial partner: Eclipse Scientific• Industrial collaborator: Robert Ginzel• Student: Mohammad Marvasti• Project Objective: Develop software &

phased array timing sequence, and calibration system for elevated temperature inspection


Phased Array Inspection of Hot Specimens (contd)

(a) velocity vs temperature(b) model of wave

propagation(c) refine delay times

(b) (c)


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Phased Array Inspection of Hot Specimens (contd)

NDT in Canada 2015 Conference

Benefits to Eclipse Scientific:1/ Sales products2/ Unique marketing tool3/ Address calibration/regulatory concerns4/ publications in trade journals5/ A skilled new employee

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Signal processing to enhance time resolution


• Industrial partner: Olympus NDT Canada• Industrial collaborator: Michael Moles, Jason Habermehl• Student: Chi-Hang Kwan• Project Objective: Sharpen echo time resolution : improve TOFD accuracy

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Signal processing to enhance time resolution (contd)

Reference case is a small echo, overlapping a larger echo, in the presence of significant noise. Similar but distinct echo profiles


Signal Processing Techniques• Wiener Deconvolution• L1 Norm deconvolution• Spectral Extrapolation• Time-frequency representation, Wigner-Ville signal distribution

Each technique is investigated by a single student, using(i) synthetic signals(ii) artificial defects (notches, drilled holes)(iii) field samples

lateral wave

defect echo


Low-noise signals on simple defects can be addressed

Raw experimental B-scan Enhanced B-scan close-ups


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Potential Benefits to Olympus NDT Canada:1/ State-of-the-art software for OMNISCAN2/ Improved instrument specifications3/ Publicity for their products

• Wesley, L., Sinclair, A., and Moles, M.D.C., “Enhanced Ultrasonic Defect Sizing Techniques using Wiener Filtering and Autoregressive Spectral Extrapolation”, Fracture 12, 2009.

• Sinclair, A.N., Fortin, J., Moles, M.D.C., et al (2010), “Enhancement of Ultrasonic Images for Sizing of Defects by Time-of-Flight Diffraction”, NDT&E Intl, 43, 258-264.

• Moles, M.D.C., Robertson, L. and Sinclair, A.N., “Further Developments in Time-Of-Flight Diffraction”, NDE-2012, Delhi, India (2012).

• Caldwell, J., Shakibi, B, Moles, M.D.C., and Sinclair, A.N., “Root Crack Sizing Using Phased Array Inspections and Autoregressive Spectral Extrapolation Signal Processing”, QNDE (2012).

• Shakibi, B., Honarvar, F., Moles, M.D.C., Caldwell., J., and Sinclair, A.N. (2012), “Resolution enhancement of ultrasonic defect signals for crack sizing”, NDT&E International 52, 37-50.

• Kwan, C-H., and Sinclair, A.N., "Echo Identification by Singular Value Decomposition of Cross Wigner-Ville Distribution", IEEE Annual Ultrasonics Symposium, Chicago (2014).

but noisy, distorted echoes?

NDE of Watermains

• Industrial partner: ANDEC/CANDET• Industrial collaborator: DeWalle• Student: Jon Lesage• Project Objective: Develop a

resonance method for detecting early stage of damage to PCCP water mains


NDT in Canada 2015 Conference 13

NDE of Watermains (contd.)Key challenges:

• Over 50,000 km of PCCP• Some pipes are 50-75 years old• Alternative NDT methods are too late• Access at interior, but damage is exterior• Pipe specs are imprecise• Surrounding soil absorbs energy• Structure is complex• Damage mechanism is complex


NDE of Watermains (contd.)• Only low frequencies penetrate Resonance Acoustic Spectroscopy

• Use signal processing to counter damping effects of soil

• But how to address uncertainties in pipe specs?


NDE of Watermains (contd.)Prototype System• Impact hammer, plus acoustic receivers mounted on axial-moving scanner

• System operates without depressurizing pipe

• To date, system has been tested only on simulated flaws,


Detection of Corrosion under Pipe Supports• Industrial partner: Groupe Mequaltech• Industrial collaborator: Gabriel Turcan• Utoronto Student: Nicholas Andruschak• Project Objective: Assess wall thinning in

pipe systems at inaccessible locations.


Corrosion detection at pipe supports (contd.)Basic Concept:Send a SH guided wave through affected zone using Electromagnetic Acoustic Transducers (EMAT’s):

I. EMAT’s couple easily to rusted pipesII. EMAT’s are well-suited to generation of shear wavesIII. EMAT’s can accommodate curved pipe surface


Corrosion detection at pipe supports (contd.)

Major InnovationsI. Switch guided wave orientation to align with pipe axis

• More accurate localization and assessment of corrosion extent• Less ambiguity in signal processing• Better sensitivity to gradual wall thinning

II. Switch to dispersive SH1 mode• Timing methods indicate overall amount of corrosion• Lower frequencies are sharply attenuated in severely thinned regions,

allowing an assessment of maximum wall loss.

III. Widen bandwidth to enhance frequency information.

A prototype system is currently nearing completion at Groupe Mequatech, Montreal


Pull-out strength of reinforcing fibers• Industrial partner: Rockwell International• Industrial collaborator: Jeff Schoenwald• Utoronto Student: Farhang Honarvar• Project Objective: Characterize pull-out

strength of fibers in reinforced compsites

strong interfacial echo from reinforcing fiber

weak interfacial echo from reinforcing fiber


Pull-out strength of reinforcing fibers (contd.)How can Rockwell get a better quantitative measure of a fiber’s pullout strength?

- Calculatedo Measured

SIC sheath

Graphite

Incident plane wave

Ti matrix


Pull-out strength of reinforcing fibers (contd.) Instead of mapping magnitude of echo signal from fiber,

map the strength of the resonance dip

Strong resonance Good fiber bonding

Weak resonance Poor fiber bonding

No interfacial echo


NDE of explosive welds• Industrial partner: Sigmabond Technologies• Industrial collaborator: Harry Sildva/Alex Szecket• Utoronto Student: Ying Fan• Project Objective: Detect intermetallic

impurities at weld interface

Explosive welds are used to join “incompatible” metals in a metallic bond, with virtually no interfacial impurities. E.g., copper cladding on aluminum;titanium cladding on steel

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NDE of explosive welds (contd.)

Cu

AlAl

Cu

Cu2Al3

The problem:Plasma “waves” can generate low pressure zones at the Cu-Al weld interface.These zones promote the generation of brittle Cu2Al3.

3.5 mm 350 m


NDE of explosive welds (contd.)NDE Concept:Characterize amplitude and spatial period of the wave structure on the interface.

Intermetallics occur when wave amplitude is large, wavelength is short.

mm

mm

Distance between wave crests (spatial period) is easily measured, but how do you determine wave amplitude?


NDE of explosive welds (contd.)

Scanning Method:1/ Use an unfocused normal beam, gated to acquire the interfacial echo.2/ Calculate the frequency spectrum corresponding to each A-scan.3/ Examine frequency interval f of resonant peaks.

CuNi d

2d = n c/f wave amplitude


NDE/QC Career Launches of Former Student

• Nicholas Andruschak - Mequalteche• Navid Badie – CANDU Energy• Adrian Boangiu – AMEC NSS• Jeff Caldwell – NSS• Chris Chaggares - VisualSonics• Daniel Kuntz – UPS Plant Engrg.• Stephanie Cloutier – Chrysler • Ying Fan – General Electric• Joel Fortin – Bpr Bechtel/TetraTech• Skerdi Frasheri – Morgan Solar Inc.• Joshua Guin - NSS• Trek Hazelton – Ont Power Gen• F. Honarvar – Prof, KNT Univ.• David Jarman – Hatch

• Maciej Jastrzebski – Hatch• Daniel Kuntz – UPS Plant Engrg.• John Macquarrie – B&W Canada• M. Marvasti – Eclipse Scientific• Koorosh Mirhkani – Hatch• Jaleel Moidu – General Electric• S. Momeni – Physical Acoustics• Amy Park – Transport Canada• Vahid Safavi – Orthodyne• Radhika Sagar - Autoliv• Kiyan Shapoori - Tessonics• John Sedo – Ont Power Generation• Mike Trelinski – IMS, OPG• Hong Wang - UTEX


Summary

A collaborative R&D project with a university lab is a good bet for industry:

1) Keep plugged in to latest advances2) training opportunities3) Develop/improvement of products4) Program is heavily subsidized by government5) Good recruitment & evaluation tool6) Avoid stagnation in your products and services

industrial –university of toronto collaboration in ... · 5/ a skilled new employee. 8 signal...

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