Matthias Goldammer

MECHANISMS AND MODELS FOR CRACK DETECTION WITH INDUCTION THERMOGRAPHY

Induction thermography is a non‐contacting, non‐destructive evaluation method with a wide range of applications. A deeper understanding of the detectability of cracks requires fundamental knowledge about the induced current density distribution in the component under test. A calculation of the current distribution provides information how much current is flowing at which location of the component, how a crack disturbs the current density, how much heat is produced at which location of the component, and how the heat diffuses to the surface. The heating process depends on the type of crack. On the one hand there are cracks which can be detected mainly by direct observation of the heating process due to an increased current density, and on the other hand there are cracks which can be detected mainly because of a modification of the heat diffusion. This paper presents an analytical model for the calculation of the current distribution, including the back‐flow current along with finite‐element calculations. F...

INDUCTION AND CONDUCTION THERMOGRAPHY: OPTIMIZING THE ELECTROMAGNETIC EXCITATION TOWARDS APPLICATION

Active thermography, using electromagnetic excitation, allows detecting defects like cracks which distort the flow of current in the component under examination. Like other thermography techniques it is rapid and reliably utilizing infrared imaging. Electric current can be used in two ways for thermography: In induction thermography a current is coupled to the component by passing an AC current through a coil which is in close proximity to the component inspected, while in conduction thermography the current is coupled directly into the component. In this paper, the specific advantages of both coupling methods are discussed, including the efficiency of the coupling and optimization strategies for testing and also the necessary algorithms required to analyze the data. Taking these considerations into account a number of different systems for laboratory and practical application were developed.

Artifact reduction in non-destructive testing by means of complementary data fusion of x-ray computed tomography and ultrasonic pulse-echo testing

In industrial non-destructive testing, x-ray computed tomography (CT) and ultrasonic pulse-echo testing play an important role in the investigation of large-scale samples. One major artifact arises in CT, when the x-ray absorption in specific directions is too intense, so that the material cannot be fully penetrated. Due to different physical interaction principles, ultrasonic imaging is able to show features which are not visible in the CT image. In this contribution, we present a novel fusion method for the complementary data provided by x-ray CT and ultrasonic testing. The ultrasonic data are obtained by an adapted synthetic aperture focusing technique (SAFT) and complement the missing edge information in the CT image. Subsequently, the full edge map is incorporated as a priori information in a modified simultaneous iterative reconstruction method (SIRT) and allows a significant reduction of artifacts in the CT image.

Analytical modeling of flash thermography: results for a layered sample

For a long time quantitative data analysis for nondestructive evaluation of material properties with flash thermography meant a simple comparison of the measured temperature to a standard at a fixed time after excitation. With the advent of modern infrared camera technology a few improved concepts for extracting measurement data were developed, but no testing technique used for industrial applications took advantage of the physical properties of thermal diffusion. We present an analytical 1-dimensional model for a multi-layer sample that predicts the time evolution of the surface temperature after excitation. Based on an experimentally confirmed model for thermography with periodic excitation, this calculation tool permits to determine parameters like layer thickness or heat conductivity taking into account the complete data set instead of a single image. For samples with a geometry and thermal properties specified before measuring, an unknown parameter could be extracted from experimental data without further calibration standards. The model is also capable of accommodating arbitrary excitation and semitransparent layers. We present calculations of different test scenarios like layer thickness measurement. Finally, we compare the model calculation to test samples with known characteristics.

Probability of detection analysis of round robin test results performed by flash thermography

Abstract Within the scope of a standardisation research project, a flash thermography round robin test that evaluates reliability, comparability and efficiency of different testing situations was performed. Data recorded at metal test specimens with flat bottom holes (FBHs) were analysed by calculating the signal-to-noise ratio (SNR) of the defect signatures in the thermograms as well as in the phase images as a function of defect parameters. A new multi-parameter probability of detection (POD) model was developed, where an â versus a continuous signal analysis was based on the linear relationship between the SNR and a multi-parameter a. This linear relationship was verified by comparison to data obtained from an analytical model that is considering lateral thermal heat diffusion as well as to data obtained by numerical simulation. The resulting POD curves for the thermograms and phase images give an estimation for the detectability of the FBHs with known geometry in steel using different equipment and obtained by different participants. By comparing the SNRs of FBHs with similar geometries, this POD model was transferred to aluminium and copper as well.

Data fusion in neutron and X-ray computed tomography

We present a fusion methodology between neutron and X-ray computed tomography (CT). On the one hand, the inspection by X-ray CT of a wide class of multimaterials in non-destructive testing applications suffers from limited information of object features. On the other hand, neutron imaging can provide complementary data in such a way that the combination of both data sets fully characterizes the object. In this contribution, a novel data fusion procedure, called Fusion Regularized Simultaneous Algebraic Reconstruction Technique, is developed where the X-ray reconstruction is modified to fulfill the available data from the imaging with neutrons. The experiments, which were obtained from an aluminum profile containing a steel screw, and attached carbon fiber plates demonstrate that the image quality in CT can be significantly improved when the proposed fusion method is used.

Artifact reduction in industrial computed tomography via data fusion

As the most stressed part of a gas turbine the first row of turbine blades is not only a challenge for the materials used. Also the testing of these parts have to meet the highest standards. Computed tomography (CT) as the technique which could reveal the most details also provides the biggest challenges [1]: A full penetration of large sized turbine blades is often only possible at high X-ray voltages causing disproportional high costs. A reduction of the X-ray voltage is able to reduce these arising costs but yields non penetration artifacts in the reconstructed CT image. In most instances, these artifacts manifests itself as blurred and smeared regions at concave edges due to a reduced signal to noise ratio. In order to complement the missing information and to increase the overall image quality of our reconstruction, we use further imaging modalities such as a 3-D Scanner and ultrasonic imaging. A 3-D scanner is easy and cost effective to implement and is able to acquire all relevant data simultaneous...

AUTOMATED INDUCTION THERMOGRAPHY OF GENERATOR COMPONENTS

Using Active Thermography defects such as cracks can be detected fast and reliably. Choosing from a wide range of excitation techniques the method can be adapted to a number of tasks in non‐destructive evaluation. Induction thermography is ideally suited for testing metallic components for cracks at or close to the surface. In power generation a number of components are subjected to high loads and stresses—therefore defect detection is crucial for a safe operation of the engines. Apart from combustion turbines this also applies to generators: At regular inspection intervals even small cracks have to be detected to avoid crack growth and consequently failure of the component. As an imaging technique thermography allows for a fast 100% testing of the complete surface of all relevant parts. An automated setup increases the cost effectiveness of induction thermography significantly. Time needed to test a single part is reduced, the number of tested parts per shift is increased, and cost for testing is reduced significantly. In addition, automation guarantees a reliable testing procedure which detects all critical defects. We present how non‐destructive testing can be automated using as an example an industrial application at the Siemens sector Energy, and a new induction thermography setup for generator components.

Induction and conduction thermography: From the basics to automated testing taking into account low and high residual stresses

Abstract Active thermography via electromagnetic excitation is a non-destructive evaluation method with a wide range of applications. It is a quick and reliable means for detecting inhomogeneities like cracks at or close to the surface of conductive components utilizing infrared imaging. Electric current can be used in two ways for thermography: In induction thermography, a current is coupled to the component without contact by passing an alternating current through a coil which is in close proximity to the component inspected; in conduction thermography, the current is coupled directly with the component. In this paper, we present a review of the basics of this non-destructive evaluation method along with several component examples and examples of inspection systems. In particular, automated testing is regarded. Additionally, sufficient detectability of cracks under low and high residual stress is discussed and compared with other surface testing methods.

Simulative Ultraschall-Untersuchung von Pitch-Catch-Messanordnungen für große zylindrische Stahl-Prüflinge und gradientenbasierte Bildgebung

Zusammenfassung Große zylindrische Stahlprüflinge werden mittels der Methode der finiten Differenzen im Zeitbereich (engl. finite differences in time domain, FDTD) simulativ untersucht. Dabei werden Pitch-Catch-Messanordnungen verwendet. Es werden zwei Bildgebungsansätze vorgestellt: ersterer basiert auf dem Imaging Principle nach Claerbout, letzterer basiert auf gradientenbasierter Optimierung eines Zielfunktionals.