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Advanced NDE Technologies for Quality Control

Advanced NDE Technologies for Quality Control. November 9 th , 2012 Dr. Jeong Na Technology Leader NDE Group 1250 Arthur E. Adams Drive Columbus, OH 43221. Advacned NDE Technologies. Matrix Phased Array (MPA) Ultrasonics Laser Based Ultrasonics Array Eddy Current

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Advanced NDE Technologies for Quality Control

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  1. Advanced NDE Technologies for Quality Control November 9th, 2012 Dr. Jeong Na Technology Leader NDE Group 1250 Arthur E. Adams Drive Columbus, OH 43221

  2. Advacned NDE Technologies • Matrix Phased Array (MPA) Ultrasonics • Laser Based Ultrasonics • Array Eddy Current • Ultrasonically Induced Thermography

  3. Linear Phased Array UT • One-Dimensional Array Configuration • Line Focusing, Steering and Electronic Scanning Piezo Elements Focusing Steering Scanning

  4. Matrix Phased Array (MPA) Technology • Provides 2-Dimensional Electronic Control of Beam: Focusing, Steering, and Scanning Each bar represents firing delay for each element

  5. 3-D MPA Probe • Convex Surface Contour • No Requirement of Steering • Less Number of Elements (8x8) • Lower Frequency (12 MHz)

  6. Automotive Resistance Spot Welds • Provides 2-D Image of Weld Nugget along with Diameter and Area Information 6 mm RSW Screen Shot

  7. Weld Nugget Diameter (0.7 mm Thickness) 10.0 8.0 UT vs Destructive 6.0 Ideal Avg. UT Dia. (mm) 95% LUS 4.0 2.0 0.0 0.0 2.0 4.0 6.0 8.0 10.0 Avg. Peel/Chisel Destructive Test Dia. (mm) 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

  8. Laser Based Ultrasonics • Non-contact • Fast Scan • Complex Geometries • Hostile Environments • High Spatial Resolution • Versatile – Very small to Very Large Parts • Laser Generation • Laser Detection • Hardware, electronics, computers

  9. Elastic Waves Sound Velocity: VL > VS > VR

  10. Weld Joint Inspection Weld Joint Butt Joint Decreasing lack of penetration along weld  Levesque et.al. “Defect Detection and Residual Stress Measurement in Friction Stir Welds using Laser Ultrasonics”, LU 2008.

  11. Mechanical Properties Honeycomb delamination and disbond Blouin et. al. “Detection of Skin Disbond in Honeycombs and Coating Detachment by Laser Tapping Technique”, LU 2008.

  12. Fundamentals of Eddy Current No Flaw With Flaw

  13. 32 Element Array Probe Scanner Spot A Spot B Array Eddy Current Technology

  14. Example - FSW Inspection • Friction Stir Welded Aluminum Plate (1” thick) • 32 Element Flexible Eddy Current Probe (Multi Frequency) FSW Scan Direction

  15. Inspection Results 20 kHz 480 kHz

  16. Ultrasonically Induced Thermography • Fast and Non-Contact Inspection • Easy to Interpret Inspection Results

  17. Ultrasonic Induced Thermography Ultrasonic Horn Temperature Sensor Through Transmission Measurement Single Side Measurement

  18. Example (Resistance Spot Welded Thin Metal Plates) Bad Weld Good Weld X-ray image showing weld nuggets (2 mm diameter RSW)

  19. Correlation to Pull Strength

  20. 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

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