SIP

The Joining and Non-destructive

Testing Centre

(JNTC)

Dr Manfred Johannes

&

Dr Annelize Botes

Thank you

1. Introduction and Background Information

2. Purpose of the JNTC

3. Scope of activities

4. Proposed JNTC structure

5. JNTC interactions & supported technologies

6. NDT activities internationally in the field of LBM / AM

7. Conclusions

Overview of the presentation

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1. Internationally the requirement for process qualification and

certification for welding, LBM, AM and NDT is becoming a standard

2. The question for which industry requires an answer is: Can the

technologies and processes utilised provide the

results and answers required?

3. The reason for this question is the outsourcing of non-core activities

and services and in many instances the experience of non-delivery by

unscrupulous technology and service providers

4. Studies such as for instance the PISC exercise, the DDT and PANI

have revealed for NDT that one needs to “do much more” to obtain the

desired results

5. Qualification and certification of quality related processes such as

laser welding, LBM / AM and NDT demand a major engineering input, to

design and develop adequate certifiable processes.

Introduction and Background Information

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1. Main purposes: Establishing a JNTC within the CSIR as a vehicle for

South African industry at large to assure localisation of laser welding

and NDT technologies and to facilitate human capital development

2. The initiative was identified in planning and establishing a CSIR

flagship programme in 2013 whereby capabilities for the project were

found to be wanting and hence had to be developed for the

programme.

3. Collaboration between various CSIR BU’s (NLC, MSM, DPSS) and the

industries involved (e.g. Eskom, Transnet, Denel, the SAAF to mention

a few) will enhance capability building in Material Science, Welding

technologies (metallic, non-metallic, composites) and NDT

4. The aim is to provide advanced theory training, design capabilities

through modelling and simulation and equipment for the qualification

and certification of processes as required by the local industries.

Purpose of the JNTC

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1. The scope of the JNTC is to establish itself as a one stop multi-

disciplinary joining technology & NDT research and development

centre for the South African industry.

2. Current and future research projects within the Centre should be

• of national interest,

• be industry related and/or driven,

• be multi-disciplinary in nature

whilst striving to promote a research culture among staff (and

research students alike) through providing and creating research

capacity.

Scope of activities

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Scope of activities

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The activities within the JNTC will strongly overlap with the following areas: • Mechanical testing (destructive), • Non-destructive evaluation (NDT), • Development of Composite

materials (specialised cladding compositions),

• Failure analysis, • Manufacturing Management

systems, • Mechatronics and Robotics, • Digital modelling techniques and

Reliability testing.

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Proposed (envisaged) structure

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JNTC interactions & supported technologies

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Work performed on European Union projects such as Cordis and Intrapid

is very much of interest:

• Cordis – Development into application of x-ray technologies including

µ -CT for AM

• Intrapid - dealing mainly with in-line NDT and Quality Control (QC)

technologies

• Eddy Current Testing

• Laser Ultrasonic Testing

• Infrared Thermographic Testing

• TWI performed the project management for both these efforts

• The results are available for migration to South Africa

• Need however funding to do this – work in progress

NDT activities internationally in the field of LBM / AM

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Development work – In-situ Ultrasonic Testing for MTU turbine blades

• Fraunhofer Institute – ITWN Kaiserslauten1 – Work in progress

NDT activities internationally in the field of LBM / AM

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Optical in-situ measurements – University Erlangen-Nürnberg2

• Work in progress

NDT activities internationally in the field of LBM

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1. Plasmo Industrietechnik4 GmbH – Vienna – Optical -, Infrared – and

Ultraviolet in-line monitoring by cameras

Types of defects

detectable

Commercial

system

NDT activities internationally in the field of LBM

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NDT activities internationally in the field of LBM

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NDT activities internationally in the field of LBM

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Ultrasonic Testing – Total focussing method

NDT activities in South Africa in the field of LBM

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NDT activities in South Africa in the field of LBM

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NDT activities in South Africa in the field of LBM

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µ - Computed Tomography – University of Stellenbosch, Wits & NECSA

Thank you

Conclutions

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1. Even though suitable NDT technologies are available in South Africa it is

still required to perform inspection development, inspection qualification

and possible certification in parallel to process development

2. Succession planning and the appointment of researchers, both local

personnel (students, post-docs and interns) must be funded

3. Appointment of a champion from overseas who can direct the technical

content and direction in the NDT development and research process is

pursued

4. Localisation and migration of the NDT technologies being developed

overseas is a must

5. Many people available to be trained and educated in NDT

6. The USA roadmap emphasizes the importance of NDT

Thank you

Roadmaps – USA3

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7. Need to define what in-situ requirements for NDT are

8. Purchase existing technology where available (and reliable) – much

faster

9. Market the JNTC capabilities to industry

Interesting reading: www.icndt.org – documents – documents store

1. The 2015 ICNDT Guide on Research and Development in NDT Non-

destructive testing: why it is important and why more research and

development should be supported (Dr Tony Dunhill Rolls Royce)

2. A landscape for the future of NDT in the UK economy

Thank you for your time

Any questions???

Conclusions - continued

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1. Online Monitoring of Additive Manufacturing Processes Using Ultrasound Hans RIEDER1,

Alexander DILLHÖFER1, Martin SPIES1, Joachim BAMBERG2, Thomas HESS2

Ultrasonic Imaging Group, Fraunhofer Institute for Industrial Mathematics ITWM;

Kaiserslautern, Germany Phone: +49 631 316004543, Fax: +49 631 316005543; e-mail:

hans.rieder@itwm.fraunhofer.de 2 MTU Aero Engines; Munich, Germany; E-mail:

joachim.bamberg@mtu.de

2. Anforderungen und Randbedingungen für den Einsatz optischer Messsysteme zur In-

Line-Prüfung additiv gefertigter Bauteile Verfasser des Aufsatzes: Harmann1,Wito;

Hausotte1, Tino; Drummer2, Dietmar; Wudy2, Katrin; 1Lehrstuhl für

Fertigungsmesstechnik, Universität Erlangen-Nürnberg 2 Lehrstuhl für Kunststofftechnik,

Universität Erlangen-Nürnberg

3. Measurement Science Roadmap for Metal-Based Additive Manufacturing WORKSHOP

SUMMARY REPORT May 2013, Prepared by Energetics Incorporated, Columbia,

Maryland for the National Institute of Standards and Technology, U.S. Department of

Commerce

4. Dem Laser auf die Finger geschaut Qualitätssicherung durch Sensoren in der industriellen

Laserschweißfertigung, Dipl.-Ing. Arnold Braunsteiner Dipl.-Ing. Daniel Nufer Plasmo

Industrietechnik GmbH, Dresdner Str. 81–85, A-1200 Wien, Österreich, Phone: +43 (0)1

2362607-0 Fax: +43 (0)1 2362607-99

References

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