Detection of internal crack growth in polyethylene pipe using guided wave ultrasonic testing

Despite the success of guided wave ultrasonic inspection for internal defect detection in steel pipes,its application on polyethylene(PE)pipe remains relatively unexplored.The growth of internal cracks in PE pipe severely affects its pressure-holding capacity,hence the early detection of internal cracks is crucial for effective pipeline maintenance strategies.This study extends the scope of guided wave-based ultrasonic testing to detect the growth of internal cracks in a natural gas distribution PE pipe.Laboratory experiments and a finite element model were planned to study the wave-crack interaction at different stages of axially oriented internal crack growth with a piezoceramic transducer-based setup arranged in a pitch-catch configuration.Mode dispersion analysis supplemented with preliminary experiments was performed to isolate the optimal inspection frequency,leading to the selection of the T(0,1)mode at 50-kHz for the investigation.A transmission index based on the energy of the T(0,1)mode was developed to trace the extent of simulated crack growth.The findings revealed an inverse linear correlation between the transmission index and the crack depth for crack growth beyond 20%crack depth.

Improving Ultrasonic Testing by Using Machine Learning Framework Based on Model Interpretation Strategy

Ultrasonic testing(UT)is increasingly combined with machine learning(ML)techniques for intelligently identifying damage.Extracting signifcant features from UT data is essential for efcient defect characterization.Moreover,the hidden physics behind ML is unexplained,reducing the generalization capability and versatility of ML methods in UT.In this paper,a generally applicable ML framework based on the model interpretation strategy is proposed to improve the detection accuracy and computational efciency of UT.Firstly,multi-domain features are extracted from the UT signals with signal processing techniques to construct an initial feature space.Subsequently,a feature selection method based on model interpretable strategy(FS-MIS)is innovatively developed by integrating Shapley additive explanation(SHAP),flter method,embedded method and wrapper method.The most efective ML model and the optimal feature subset with better correlation to the target defects are determined self-adaptively.The proposed framework is validated by identifying and locating side-drilled holes(SDHs)with 0.5λcentral distance and different depths.An ultrasonic array probe is adopted to acquire FMC datasets from several aluminum alloy specimens containing two SDHs by experiments.The optimal feature subset selected by FS-MIS is set as the input of the chosen ML model to train and predict the times of arrival(ToAs)of the scattered waves emitted by adjacent SDHs.The experimental results demonstrate that the relative errors of the predicted ToAs are all below 3.67%with an average error of 0.25%,signifcantly improving the time resolution of UT signals.On this basis,the predicted ToAs are assigned to the corresponding original signals for decoupling overlapped pulse-echoes and reconstructing high-resolution FMC datasets.The imaging resolution is enhanced to 0.5λby implementing the total focusing method(TFM).The relative errors of hole depths and central distance are no more than 0.51%and 3.57%,respectively.Finally,the superior performance of the proposed FS-MIS is validated by comparing it with initial feature space and conventional dimensionality reduction techniques.

Determining rock crack stress thresholds using ultrasonic through-transmission measurements

The crack initiation stress threshold is widely used in excavation industries as rock spalling strength when designing deep underground structures to avoid unwanted brittle failures.While various strain-based methods have been developed for the estimation of this critical design parameter,such methods are destructive and often requires subjective interpretations of the stress–strain curves,particularly in rocks with pre-existing microcracks or high porosity.This study explore the applicability of non-destructive ultrasonic through-transmission methods for determining rock damage levels by assessing the changes in transmitted signal characteristics during loading.The change in velocity,amplitude,dominant frequency,and root-mean-square voltage are investigated with four different rock types including marble,sandstone,granite,and basalt under various stress levels.Results suggest the rate of signal variations can be reliably used to estimate crack closure and crack initiation stress levels across the tested rocks before failure.Comparison of the results between the conventional techniques and the new proposed methods based on ultrasonic monitoring are further discussed.

长输管道全自动焊接AUT检测典型缺陷分析

近年来全自动焊接方法在大管径长输管道中得到了大量应用,目前,国内外对长输管道全自动焊接的主要检测方式是全自动超声检测(AUT)技术。主要介绍长输管道全自动焊接的典型缺陷类型及典型缺陷在AUT图谱中的图像显示和分析,以为同行正确地判别此类缺陷提供参考。

Nondestructive Testing and Characterization of Residual Stress Field Using an Ultrasonic Method

To address the difficulty in testing and calibrating the stress gradient in the depth direction of mechanical components, a new technology of nondestructive testing and characterization of the residual stress gradient field by ultrasonic method is proposed based on acoustoelasticity theory. By carrying out theoretical analysis, the sensitivity coefficients of different types of ultrasonic are obtained by taking the low carbon steel（12%C） as a research object. By fixing the interval distance between sending and receiving transducers, the mathematical expressions of the change of stress and the variation of time are established. To design one sending-one receiving and oblique incidence ultrasonic detection probes, according to Snell law, the critically refracted longitudinal wave（LCR wave） is excited at a certain depth of the fixed distance of the tested components. Then, the relationship between the depth of LCR wave detection and the center frequency of the probe in Q235 steel is obtained through experimental study. To detect the stress gradient in the depth direction, a stress gradient LCR wave detection model is established, through which the stress gradient formula is derived by the relationship between center frequency and detecting depth. A C-shaped stress specimen of Q235 steel is designed to conduct stress loading tests, and the stress is measured with the five group probes at different center frequencies. The accuracy of ultrasonic testing is verified by X-ray stress analyzer. The stress value of each specific depth is calculated using the stress gradient formula. Accordingly, the ultrasonic characterization of residual stress field is realized. Characterization results show that the stress gradient distribution is consistent with the simulation in ANSYS. The new technology can be widely applied in the detection of the residual stress gradient field caused by mechanical processing, such as welding and shot peening.

Progress on the ultrasonic testing and laser thermography techniques for NDT of tokamak plasma-facing components

During manufacturing and operation, different kinds of defects, e.g., delamination or surface cracks, may be generated in the plasma-facing components (PFCs) of a Tokamak device. To ensure the safety of the PFCs, various kinds of nondestructive testing (NDT) techniques are needed for different defect and failure mode. This paper gives a review of the recently developed ultrasonic testing (UT) and laser thermography methods for inspection of the delamination and surface cracks in PFCs. For monoblock W/Cu PFCs of divertor, the bonding quality at both W-Cu and Cu- CuCrZr interfaces was qualified by using UT with a focus probe during manufacturing. A noncontact, coupling-free and flexible ultrasonic scanning testing system with use of an electromagnetic acoustic transducer and a robotic inspection manipulator was introduced then for the in-vessel inspection of delamination defect in first wall (FW). A laser infrared thermography testing method is highlighted for the on-line inspection of delamination defect in FW through the vacuum vessel window of the Tokamak reactor. Finally, a new laser spot thermography method using laser spot array source was described for the online inspection of the surface cracks in FW.

Thickness measurement approach for plasma sprayed coatings using ultrasonic testing technique

The special ultrasonic testing system has been developed for thickness measurement of plasma sprayed coatings. The ultrasonic immersion method was used to obtain stable coupling condition and avoid other disadvantages of contact method. Spherical acoustic lens were designed to focus ultrasonic beam so as to improve beam directivity and concentrate ultrasonic energy. To increase testing precision and avoid mussy wave signals, moderate pulse width and frequency of the transducer has been selected. The displacement of transducer in X-Y-Z directions was precisely manipulated by step-controlled system to insure the accuracy of focus length and repetition of measurement. Optimized testing conditions (with the transducer of center frequency of 10 MHz and crystal diameter of 8 mm, focus length of 9.5 mm, diameter of focal column of 0. 1 mm and length of focal column of 0.27 mm) were selected to determine the thickness between 285 -414 μm of ZrO2 coatings plasma sprayed on the nickel based superalloy. The frequency interval of the periodic extremums in ultrasonic power spectra decreases with increasing coating thickness. The ultrasonic results accord with those of metallographical method.

Laser ultrasonic testing for near-surface defects inspection of 316L stainless steel fabricated by laser powder bed fusion

The laser powder bed fusion(L-PBF)method of additive manufacturing(AM)is increasingly used in various industrial manufacturing fields due to its high material utilization and design freedom of parts.However,the parts produced by L-PBF usually contain such defects as crack and porosity because of the technological characteristics of L-PBF,which affect the quality of the product.Laser ultrasonic testing(LUT)is a potential technology for on-line testing of the L-PBF process.It is a non-contact and non-destructive approach based on signals from abundant waveforms with a wide frequency-band.In this study,a method of LUT for on-line inspection of L-PBF process was proposed,and a system of LUT was established approaching the actual environment of on-line detection to evaluate the method applicability for defects detection of L-PBF parts.The detection results of near-surface defects in L-PBF 316L stainless steel parts show that the crack-type defects with a sub-millimeter level within 0.5 mm depth can be identified,and accordingly,the positions and dimensions information can be acquired.The results were verified by X-ray computed tomography,which indicates that the present method exhibits great potential for on-line inspection of AM processes.

Ultrasonic TOFD testing for aluminum alloy weld of thick plate

The ultrasonic time of flight diffraction (TOFD) testing method for aluminum alloy weld of thick plate was introduced, and the basic defect image features of crack in shape at different positions A, B, C were discussed. The TOFD testing for weld joints was carried out. The results show that the TOFD method has a good measurement accuracy and a good ability of finding the defect of crack in shape.

Ultrasonic Nondestructive Testing of Superplastic Solid-State Welding Joint for Different Steels

Based on quantitative microscopic examinations of welds and welding rate for different steels(40Cr and T10A) joint,which possess the ultra-fine microstructure after high frequency hardening(HFH) and salt-bath cyclic quenching(SCQ),the suitable defect grey scale threshold value was determined,and the welding rate of superplastic solid-state welding of different steels(40Cr and T10 A steel) was systematically inspected and analyzed by means of self-made ultrasonic imaging inspection system.The experimental results showed that the superplastic solid-state weld of different steels can be inspected more accurately,reliably and quickly by this system,and the results were in good accordance with that of metallographic observation.The welding rate of superplastic welding is in linear relation with tensile strength of joint.

Optimization of Ultrasonic Extraction Process of Oenanthe benghalensis Polysaccharide by Orthogonal Test

[Objectives] The research aimed to explore extraction method of Oenanthe benghalensis polysaccharide,and determine the optimal process of its ultrasonic extraction by orthogonal test. [Methods] Phenol-sulfuric acid method was used to determine polysaccharide's content. Based on single-factor experiment and orthogonal test,the influences of solid-liquid ratio( A),ultrasonic extraction temperature( B),ultrasonic power( C) and ultrasonic time( D) on extraction rate of O. benghalensis polysaccharide were studied,and the optimal process of ultrasonic extraction was selected. [Results] The influence order of solid-liquid ratio( A),ultrasonic extraction temperature( B),ultrasonic power( C) and ultrasonic time( D) on extraction rate of O. benghalensis polysaccharide was A > D > B > C. Via the orthogonal test,it was determined that the optimal extraction condition of O. benghalensis polysaccharide was as below: solid-liquid ratio 1∶ 25( g/mL),extraction temperature 60℃,extraction power 80 W,extraction time 40 min. Under the condition,extraction rate of O. benghalensis polysaccharide was9. 80%. [Conclusions] The process could provide the reference basis for extracting and producing O. benghalensis polysaccharides.

Ultrasonic testing for laser welded joint of stainless steel

Two dimensional scan for laser welded joint of stainless steel was implemented according to the reflection characteristics of ultrasonic. B-scan imaging technique was applied to characterize the fusion state in the joint and distinguish welding detects such as incomplete penetration. Calculation of weld width at the interface of the two plates and imaging of the weld cross section were accomplished. Experimental results show that rapid nondestructive testing can be achieved by this method with threshold value of 30% attenuation degree. The calculation error is less than 0. 25 mm.

Experimental Study on the Ultrasonic Testing including Porosity of Rock Damage Characteristics

Cement mortar specimens are used to simulate the fracture of rock material under uniaxial compression test, using the ultrasonic instrument measurement test process, the waveform and wave velocity results along with the change of specimen fracture extension are obtained. Experimental results show that at 0 MPa, there are micro-defects in the specimen, leading to the irregular change of the waveform of the measuring points 4# and 5#;At 1 - 4 MPa, there is no crack on the surface of the specimen, the waveform of ultrasonic wave is stable, and the velocity of each point increases with the increase of the strain, but the measuring point increases the wave velocity when the load is applied;When the specimen surface cracks, expect the waveform of measuring point 4# and 5# change in irregularities, the measuring point 2# waveform also changes irregularly and measuring point of the wave velocity has decreased;At the crack propagation stage, ultrasonic wave also changes irregularly along with the expansion of crack, wave velocity with the increase of the strain is also obvious downward trend;When the crack penetrates the whole specimen, the waveform of each measuring point changes abnormally, the continuity is bad, the waveform is irregular and the measured wave velocity is low.

NUMERICAL SIMULATION OF ULTRASONIC NONDESTRUCTIVE TESTING FOR WELDS

A computer simulation technique for ultrasonic propagation is utilized for the simulation of ultrasonic nondestructive testing (NDT). In this paper, one goal of the simulation is to compute ultrasonic field radiated by arbitrary transducers into pieces under examination. The other simulates a testing experiment. The simulation approach is based on the model for the computation of the ultrasonic field in isotropic media radiated from actual NDT transducers. After the field is known, remaining to be modeled is the interaction between this field and the scatters (defect) and the echo structure. The model of beam-defect interaction is based on the Kirchhoff’s diffraction approximations theory applied to elastodynamics. We assumed that the incident wave fronts on the defect are plane in the case of a focused immersed transducer and material is isotropic and homogeneous. The simulating results demonstrate that the model in ultrasonic NDT of welds is practical in further research and useful in optimizing testi

Rapid ultrasonic C-scan on image test for spot welding based interpolation

In this paper, ultrasonic C-scan test of spot welds for stainless steel has been studied. It is concluded that large scanning step length contributes to high testing efficiency, however, the low-resolution C-scan image generated cannot be used to assess spot welding quality reliably. Based on bicubic image interpolation, the C-scan image in low resolution with the large step length 1 000 ~xm is subdivided and reconstructed. By this means, the C-scan image resolution is greatly enhanced and testing results obtained are satisfactory, realizing rapid assessment of spot welds. The results of rapid ultrasonic C-scan test fit the actual metallographic measured value well. Mean value of normal distribution of error statistics is O. 006 67, and the standard deviation is O. 087 11. Rapid ultrasonic C-scan test based on image interpolation is of high accuracy and excellent stability.

Feasibility of differentiating defect signals of ultrasonic testing for laser weld based on independent component analysis theory

Separating noise from observed signals was studied.When the small defect in the T-shape laser welding joint was inspected by ultrasonic testing system adopting independent component analysis(ICA) theory to process the signals.The principle of automatic ultrasonic testing signals processing and negentropy law of ICA were introduced.The experimental data were processed using relative analysis tools and results showed that the ICA could separate defects signals from noise effectively in laboratory.

The Testing Strength Curves of Lightweight Aggregate Concrete by Rebound Method and Ultrasonic-rebound Combined Method

The strength curves of lightweight aggregate concrete （LWAC） were tested based on detecting LWAC with density of 1 400-1 900 kg/m3 and LWAC with strength grade of LC15-LC50 by rebound method and ultrasonic-rebound combined method.The results show that the common measured strength curves tested by above two methods can not satisfy the required accuracy of LWAC strength test.In addition,specified compressive strength curves of testing LWAC by rebound method and ultrasonic-rebound combined method are obtained,respectively.

Monitoring of polymeric membrane fouling in hollow fiber module using ultrasonic nondestructive testing

This study describes the development of novel protocols extending the real-time ultrasonic reflectometry(UTDR) for the detection of membrane fouling in hollow fiber module during ultrafiltration(UF) of oily water treatment. A specially designed acoustic sensor with a frequency of 2.5 MHz was used. The hollow fiber membranes used were polysulphone(PSf) UF membranes with MWCO 40 kDa. The wastewaters with three different oily concentrations of 100, 500 and 1 000 mg/L were investigated. Diesel oil was utilized as the primary foulant. The results show that the permeate flux declines with operation time and its value becomes lower with the increase of the oily concentration in wastewater. It is found that ultrasonic measurement can detect the fouling and cleaning processes. A new signal analysis protocol-ultrasonic reflected energy was developed. Ultrasonic reflected energy obtained indicates the deposition of oily layer as a function of operation time and its removal after cleaning. The overall flux decline is reasonably correlated with the changes in ultrasonic reflected energy. This research provides the evidence that the ultrasonic reflectometry technique is capable of monitoring membrane fouling and cleaning in hollow fiber modules.

Simulation as a Support for Ultrasonic Testing

Ultrasonic testing is a very important non-destructive method for testing components for safety of nuclear power plants and other security and delicate parts in other industries. Nowadays, thanks to the development of computer technology, it is possible to simulate processes which occur during ultrasonic testing. That is why numerical simulations are becoming an integral part of non-destructive testing. Simulations are used to determine parameters of ultrasonic examination, especially parameters of probes and scan plan and also in the analysis of results. They are used in such cases, when it is necessary to verify applicability of probes and methods. This verification could be provided on the weld and test block which are not manufactured. It could be also provided on defects, which are not manufactured in test block, but their presence is possible in given weld joint. Simulations are very useful for verifying the propagation of ultrasonic signal in given area (e.g. weld area). If movement of probe is limited, possibility of whole volume scan should be verified.

Ultrasonic Testing Combined with Pattern Recognition for the Detection of Kissing Bonds

Kissing bonds are defects in the adhesive bonds with intimate contact of touching surface but considerably lowered shear strength. Their detection specifically in the aerospace area is so not satisfactory. Usually, kissing bonds are inconspicuous in ultrasonic C-scans. However, the determination of attributes in the time domain and the frequency domain of an ultrasound signal provides the opportunity to derive a pattern for bonded area. Deviations from the pattern found in inconspicuous bonding areas indicate kissing bonds. The survey described here deals with the manufacturing of adhesively joint samples that purposefully include kissing bonds, as well as potential solutions for detecting them through ultrasonic testing combined with pattern recognition. The properties of the epoxy-based adhesive were varied by changing the mixing ratios between resin and hardener. Samples with a mixing ratio far apart from the manufacturer’s recommendation with an inconspicuous appearance in a C-scan, but low shear strength values were taken for further evaluation. After a definition and learning phase, a 100 percent hit rate to separate good bondings from kissing bonds could be derived in a blind test. The discriminating feature found is due to the frequency shift between good and kissing bonds as well as the relative amplitude of the second peak.