Board of Directors

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Room: Harris | 9:00 AM Saturday, October 27, 2018

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Standards Development (closed)

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Room: Galveston A | 10:00 AM Saturday, October 27, 2018

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President's Reception (closed)

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Room: Fort Bend | 5:30 PM Saturday, October 27, 2018

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Bylaws Ad Hoc (closed)

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Room: Chambers C | 7:30 AM Sunday, October 28, 2018

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International Forum (closed)

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Room: Houston III | 10:00 AM Sunday, October 28, 2018

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International Ad Hoc (closed)

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Room: Liberty B | 5:30 PM Sunday, October 28, 2018

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International Reception (closed)

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Room: Harris | 8:00 PM Sunday, October 28, 2018

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SOC Officers and Division Chairs

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Room: Brazoria | 8:00 AM Sunday, October 28, 2018

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Microwave Committee

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Room: Galveston B | 8:00 AM Sunday, October 28, 2018

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SOC Membership Division

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Room: Brazoria | 8:30 AM Sunday, October 28, 2018

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SOC Outreach Division

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Room: Brazoria | 9:30 AM Sunday, October 28, 2018

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SNT-TC-1A Review

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Room: Galveston A | 10:00 AM Sunday, October 28, 2018

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SOC Section Management Division

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Room: Brazoria | 10:30 AM Sunday, October 28, 2018

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Education Division

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Room: Liberty B | 11:00 AM Sunday, October 28, 2018

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SOC Regional Directors Division

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Room: Brazoria | 11:30 AM Sunday, October 28, 2018

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Engineering Education

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Room: Galveston B | 12:00 PM Sunday, October 28, 2018

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SNT-TC-1A Interpretation Panel (closed)

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Room: Galveston A | 1:00 PM Sunday, October 28, 2018

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Certification Management Council (closed)

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Room: Clear Lake | 9:00 AM Sunday, October 28, 2018

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ISO 9712 (closed)

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Room: Chambers C | 12:00 PM Sunday, October 28, 2018

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A Complete Calibration and Sizing Guide for Industrial Applications of the Full Matrix Capture/Total Focusing Method

Presenting author(s): Mr Mohammad Marvasti

Co-Authors:

Room: N/A | 9:00 AM Monday, October 29, 2018

Widespread adoption of the Full Matrix Capture (FMC) technique in the Nondestructive Testing (NDT) Industry has been somewhat hindered by the lack of code accepted calibration and sizing techniques for FMC based inspections. As a step towards establishing universal calibration and sizing standards, Acuren’s Research and Development Group present their internal guidelines for calibrating FMC inspection data. The method described is a step by step, comprehensive guide which details probe/wedge delay calibration, amplitude correction, sizing procedures and specification of coverage. It is shown that the combined effects of sensitivity, element beam profile (directivity/attenuation) and finite aperture effects are most effectively calibrated together by applying a synthetic gain correction. This correction procedure, which is directly analogous to a standard Phased Array TCG, involves measuring the stacked image amplitude originating from identical side drilled holes at different positions relative the probe aperture (true depth and distance from the probe centerline) and then computing the appropriate amplitude correction factor to set all target amplitudes to 80% - pixel amplitudes elsewhere in the domain are then corrected by interpolation from measured gain corrections. It is demonstrated that the dB drop sizing criterion is not generally uniform throughout the entire imaging domain, rather it needs to be specified as a function of target position with respect to the probe aperture. The proposed amplitude correction and sizing techniques are evaluated with respect to relevant phased array codes, from which the calibratable coverage range of a given FMC inspection system is specified.

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IRRSP (closed)

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Room: Galveston B | 9:00 AM Monday, October 29, 2018

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Infrastructure

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Room: Liberty A | 9:00 AM Monday, October 29, 2018

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Shear-Wave Ultrasonic Inspection of Metallic Structures Developing Empirical Models for Estimating Capability

Presenting author(s): Mr John C Brausch

Co-Authors: Mr John McClure

Room: N/A | 9:00 AM Monday, October 29, 2018

Shear-wave ultrasonics is a non-destructive inspection technique used to detect subsurface fatigue cracks extending from features such as fastener holes, internal lug bores and other internal structural features. Implementation of effective ultrasonic inspection solutions for detection of fatigue cracks requires considerable homework and resources particularly if detection capability must be quantified. Execution of probability of detection studies to estimate detection capability is not common due to the complexity of many applications, lack of resources to generate the required data, and the drive for rapid implementation of time critical inspections. This paper describes the sources of ultrasonic response variability that prevents establishing standard estimates of detection capability. This paper also outlines an approach for generating rapid estimates of detection capability for shear-wave ultrasonics on metallic structures that incorporates laboratory measures of crack-to-crack scatter, compressive stress effects, human factors and estimates of probability of inspection. Finally, an example application of this approach will be highlighted.

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Digital inspection of multi-material industrial parts

Presenting author(s): Mr Patrick Barthelemy

Co-Authors: Mr Peter Westenberger

Room: N/A | 9:00 AM Monday, October 29, 2018

Dimensional metrology on digital CT model of mono-material industrial parts is based on determination of the interface between air and the part. Precise determination of this surface can be difficult due to acquisition artefact that can include noise, partial volume effect, streaks, or beam hardening for instance. Different methods allows for adjustment of the interface based on an initial iso-surface that can use different thresholds such as local minima, ISO50 or Otsu. In the case of multi-materials part, the problem is even more complex as the intensity range of the CT for each component can overlap and a single threshold can belong to multiple materials. This talk will demonstrate different approaches and result of segmentation on multi-material CT data and how precise interface between each material can be extracted.

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Developing Advanced PAUT and TFM Methods on High Performance and Small Size Open Electronics

Presenting author(s): Mr Gavin Dao

Co-Authors: Mr Remi Lallement, Dr Dominique Braconnier

Room: N/A | 9:30 AM Monday, October 29, 2018

(We will submit official abstract on Monday) Non-destructive ultrasonic testing has developed an important development in new imaging techniques (focusing at any point, migration, penalized approaches, etc.). Nevertheless, most of the electronics on the market do not allow access to raw data and therefore the development of new techniques. This communication therefore presents an open and flexible electronic platform for the development and implementation of new imaging methods. This allows you to completely parameterize the electronic equipment and to have access to all the raw data.

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Probability of Detection Analysis for Hit/Miss Data

Presenting author(s): Mr Scott Follett

Co-Authors:

Room: N/A | 9:30 AM Monday, October 29, 2018

Probability of Detection Analysis for Hit/Miss Data is critical for determining the quality of non-destructive tests to find defects in welds, materials, components, or systems. ASTM E2862 is the Standard that is widely specified and used while conducting non-destructive testing. Many industries, especially when the inspection’s success at finding defects is critical to safety or quality, specify that the standard must be used. A prime challenge is to collect data and meet the requirements of the ASTM Standard. Scott will go over the standard and highlight key requirements. He will then go through an example of how to collect, analyze, and meet the requirements using Microsoft Excel. After the presentation, those who attend can expect to become familiar with standard and the tools that will enable the organization to meet those standards. If the participants have data, Scott will provide a real time analysis during the question and answer period. He will also be available after the presentation to answer specific questions and discuss details from participants. Scott Follett is a Six Sigma Master Black Belt currently teaching Six Sigma, engineering, and quality courses at Arkansas Northeastern College. In his thirty years of experience as a maintenance test pilot in the military, design engineer, quality manager, and six sigma. All of which used data from non-destructive tests. He is intimately aware of ASTM E2862 through his consulting work for a company that uses the standard to inspect for weld defects.

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Failure analysis of ultrasonic parking sensors by X Ray Computed Tomography

Presenting author(s): Mr Miguel Neri

Co-Authors:

Room: N/A | 9:30 AM Monday, October 29, 2018

Automotive ultrasonic parking sensors were analyzed using X- ray computed tomography (XCT or microtomography), to determine if there were internal failures generated on the soldering process between copper wires and piezoelectric ceramic on these sensors. This paper reports the use of X-ray Radiography, and computer image processing for the study of internal defects, by using X-ray tomography, internal defects like pores, cracks, holes, and solder bridging may be identified (1-2). If coupled with a real time radiographic detector and image processor, X-ray technology allows instantaneous radiographic imaging and semi-automatic or full automatic inspection. The failure Analysis was conducted on six produced test samples, showing that the application of XCT as a method of quality control of specimens, produced by electronic packaging, offers a wide range of possibilities to detect defects within materials. There were determined that five sensors contain internal defects on the soldered joints, between the copper wire, and the piezo electric ceramic covered with silver paint, as shown on the computed tomography. Accuracy of XCT method strongly depends on the size of the samples analyzed, but the possibility of obtaining information in 3D nondestructively shows considerable advantages of XCT method over traditional metallographic cross-sectional analysis, that show only images on 2D on 1 determined cutting plane. The thickness of the silver layer was increased, so that there was a better union between the copper wire and the ceramic wafer coated with silver paint.

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Non-Linear Ultrasound for NDT

Presenting author(s): Mr Ewen Carcreff

Co-Authors: Dr Dominique Braconnier

Room: N/A | 10:00 AM Monday, October 29, 2018

(We will submit official abstract on Monday) Non-Linear ultrasound is a next generation algorithm for detecting anomalies that are frequently missed by traditional ultrasound techniques.

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Magnetic Flux Leakage

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Room: Liberty B | 10:00 AM Monday, October 29, 2018

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Influence of the defect characteristics on the inspection reproducibility of automated testing machines

Presenting author(s): Mr Thomas Wurschig

Co-Authors: Mr Christof Breidenbach, Mr Benjamin Hoemske, Mr Rene Pfortje

Room: N/A | 10:00 AM Monday, October 29, 2018

The repeatability and reproducibility of an inspection is one of the key figures that determine the performance and quality of an automated ultrasonic testing machine. The measurement procedure applied during the commissioning of these machines is simple: according to valid standards and agreement between the parties, a number of inspection runs are carried out on a reference sample, typically a calibration standard that has been used to set up the machine. The measurement data per reference defect collected during these runs exhibit a characteristic variation. Typically, a limit for the maximum variation is defined as an acceptance criterion assuming statistical variations, which gives rise to a mostly Gaussian distribution of these variations around the average value. However, non-Gaussian parts can influence the measured reproducibility. One of the major sources of non-Gaussian variations is the quality of the reference defect in the calibration standard, which by itself can distort the performance results of the testing machine. This paper presents an in-depth investigation on the ultrasonic reflection characteristics of reference defects and compares those to the obtained reproducibility values for the same reference defects. A correlation process based on the extraction of probability functions links the ultrasonic reflection behavior directly to the reproducibility of the inspection. Using this process, it is possible to understand and define the limits of the achievable reproducibility with a given reference defect. Furthermore, the defect homogeneity is introduced as a quantitative measure allowing the classification of the quality of the manufactured reference defects within a calibration standard. The method is based on the evaluation of high-resolution C-scans. Given results were obtained with USIP|xx automated testing machines taking benefit of the high quality of inspection and the possibility to perform a detailed analysis of the reference defects under production conditions on-site with the same setup as later used for the inspection runs.

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High Performance Cone Beam Computed Tomography (CBCT) Reconstruction Platform for Non-Destructive testing purposes

Presenting author(s): Mr Oleg Konings

Co-Authors:

Room: N/A | 10:00 AM Monday, October 29, 2018

We present a high-performance Cone Beam Computed Tomography (CBCT) reconstruction platform designed specifically for Non-Destructive testing purposes (NDT). This platform includes GPU accelerated implementations of the filtered back projection algorithm (FDK), the forward projection algorithm, iterative reconstruction (Ordered Subset Expectation Maximization), and image processing convolutions/filters. These modular tools can be combined in novel ways so that the design and testing of new approaches for CBCT reconstruction and artifact reduction are feasible in short periods of time. For example we built an effective beam hardening artifact reduction process which reduces streaks, cupping and false air enhancement by as much as 65%. The software application was optimized to handle very large input projection sets and reconstructs to a 20483 volume in less than 90 seconds (including all file operations and memory copies). When using our OSEM iterative reconstruction implementation we only required half the number of input projections that would be necessary for an equivalent FDK reconstruction (based on visual assessment of image quality). This functionality of the application can reduce the long CBCT acquisition time by using fewer projections or fewer photons, increasing the CT scanner utilization. Beam hardening artifact correction can be used in conjunction with either the FDK or iterative reconstruction to further improve image quality. The application is able to use multiple GPUs in a large cluster or in a single workstation, taking advantage of the parallelizable nature of these reconstruction algorithms. Project funded by the Air Force Research Laboratory contract #FA9300-17-P-1007.

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NDT Applications using PAUT and TFM

Presenting author(s): Dr Guillaume Neau

Co-Authors:

Room: N/A | 10:30 AM Monday, October 29, 2018

Flange-, pin-, bolt -inspections are growing applications of the NDT market. There are currently numerous techniques for the inspection of sealing surfaces using regular phased-array ultrasound techniques (PAUT). M2M has implemented multiple total focusing method (TFM) techniques for the inspection of these structures. This article describes how the inspections can be achieved with higher resolution and repeatability using TFM-capable flaw detectors. A comparison between standard PAUT and TFM imaging is also discussed. As both of these ultrasound techniques have pros and cons depending on the inspection case, the competitive advantage of offering both in portable units is illustrated.

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Thinner-Wall Volumetric Weld Inspections A Best Practices Approach

Presenting author(s): Mr Robert J Raimondi

Co-Authors:

Room: N/A | 10:30 AM Monday, October 29, 2018

Ultrasonic Phased Array and TOFD (Time of Flight Diffraction) techniques should replace Radiographic Testing (RT) as the method of choice in many NDT applications, especially thinner-wall welds. Factors leading this charge include quality, cost, speed, resolution, employee safety, and code compliance. This presentation provides solid UT and X-Ray test data proving the advantages of UT and exposing the limitations of RT. We will explore and compare the physics, resolution, and sensitivity of these two volumetric inspection methods. Further information for AUT will be presented and discussed using application data and personal experience. This will include Probability of Detection (POD) studies, a formal POD proposition, and a review of code compliance requirements. Traditionally, when considering UT in lieu of RT people believed there were little economic advantages or only a limited supply of AUT technician’s delivering marginal results. Times have changed and now it’s obvious these evolved UT techniques, Phased Array and TOFD simply outperform RT and improve weld quality. A thorough application comparison review will give presentation attendees the needed understanding to draw their own conclusion, that given an NDT method choice, choosing UT first is the best practice approach.

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Exposure Factors for Film, Computed, and Digital Detector Array Radiography

Presenting author(s): Mr Brian S White

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Room: N/A | 10:30 AM Monday, October 29, 2018

Exposure factors (R factors) have been utilized for decades to provide guidance in gamma radiography film applications. A starting exposure time is calculated for a specific source type, activity, steel thickness, desired exposure for a target film density or pixel value, and source-to-detector distance (SDD). Exposure factors exist for film, however very little information is available for computed radiography (CR) and digital detector array radiography (DDA) technologies. This paper publishes R factors for Carestream NDT films, CR systems, and DDA systems utilizing Iridium, Selenium, and Cobalt radioisotopes. In addition, this paper presents established procedures for determining R factors for specific system conditions.

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NDT Reliability Studies

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Room: Chambers C | 11:00 AM Monday, October 29, 2018

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Ultrasonics

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Room: Brazoria | 12:00 PM Monday, October 29, 2018

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Materials Evaluation

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Room: Galveston A | 12:00 PM Monday, October 29, 2018

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Infrared/Thermal

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Room: Liberty B | 1:00 PM Monday, October 29, 2018

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NDT Handbook Development

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Room: Galveston A | 1:30 PM Monday, October 29, 2018

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Guided Wave Testing

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Room: Liberty A | 2:00 PM Monday, October 29, 2018

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RT Handbook Subcommittee

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Room: Galveston A | 2:30 PM Monday, October 29, 2018

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Electromagnetic Testing

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Room: Galveston B | 3:00 PM Monday, October 29, 2018

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ISQ Program - Oil & Gas (closed)

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Room: Galveston A | 3:30 PM Monday, October 29, 2018

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Aerospace

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Room: Liberty A | 4:30 PM Monday, October 29, 2018

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Pan-American Federation (closed)

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Room: Brazoria | 10:00 AM Monday, October 29, 2018

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Past Presidents (closed)

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Room: Harris | 12:00 PM Monday, October 29, 2018

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Audit Committee (closed)

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Room: Galveston B | 1:00 PM Monday, October 29, 2018

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Succession Planning (closed)

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Room: Harris | 1:30 PM Monday, October 29, 2018

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JSNDI/ASNT Symposium

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Room: Liberty B | 4:00 PM Monday, October 29, 2018

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Research Council Executive Committee (closed)

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Room: Liberty A | 11:00 AM Monday, October 29, 2018

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Research Council Dinner Meeting (closed)

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Room: Harris | 6:30 PM Monday, October 29, 2018

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An CDE Engineering Imitative

Presenting author(s): Mr Ward D Rummel

Co-Authors:

Room: N/A | 1:00 PM Monday, October 29, 2018

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Advanced X-ray Computed Tomography in Additive Manufacturing

Presenting author(s): Ms Shana Telesz

Co-Authors:

Room: N/A | 1:00 PM Monday, October 29, 2018

Additive manufacturing is increasingly being utilized for producing high-performance parts, such as turbine blades, heat exchangers, medical implants and other complex components. The technology drives a greater need for design and component validation, and often you need critical data throughout various stages of the additive value chain. Prior to manufacturing, powder for metal printing can be analyzed in terms of size distribution, sphericity, foreign particles and porosity inside the grains. After a build, trapped powder should be identified to allow for removal before subsequent heat treatments. You may also want to visualize and measure internal features on a final component to understand variations in as-built vs as-designed, relative positioning of porosity or wall thicknesses of internal structures. This session explores the critical role computed tomography (CT) plays in the value chain to optimize process parameters, increase design cycle times and provide valuable data on the quality of the components.

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Non-Contact Ultrasonic Quality Analysis of Large Finished Aerostructures

Presenting author(s): Mr Anuj M Bhardwaj

Co-Authors:

Room: N/A | 1:00 PM Monday, October 29, 2018

Carbon fiber composite aerospace structures are growing in prevalence due to decreasing costs and high performance; fuel efficiency and strength. However, non-destructive testing systems for quality analysis (QA) of finished structures remains expensive and cumbersome, primarily accomplished through the use of ultrasonic squirting systems which replicate the effects of immersion ultrasound. While these systems provide useful and detailed information, their practical use is limited and cannot keep up with demands for increased volumes of composite materials for the growing spacecraft, commercial, and military aerospace industry. Non-contact ultrasound (NCU) is a growing field, but until recently has primarily been used for quality control of flat materials or research and development for curved structures. However, through the combination of sophisticated robotics and high sensitivity non-contact ultrasound systems, a low cost, high-performance method of final inspection is now available for composite aerospace products. The Ultran Group, a non-contact ultrasonic product manufacturer and Genesis Group, a robotic systems integrator, have partnered to create and deploy industrial non-contact systems for high resolution QA of carbon fiber composite structures, such as attenuative and multi-layer materials. Initially implemented for QA of rocket payload fairing structures, the configuration of these systems is in through transmission. By utilizing efficient high sensitivity non-contact ultrasonic transducers and systems, the signal to noise ratio is boosted, enabling inspection of very thick substrates with high acoustic attenuation. However, for the purpose of detecting delamination between the skin and core of multi-layer panels, a same-side pitch-catch configuration is also under development. This exciting new application of advanced technology presents a new modality for non-destructive inspection (NDI) of finished aerospace structures.

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Qualifications and Role of an NDE Engineer

Presenting author(s): Mr Ward D Rummel

Co-Authors:

Room: N/A | 1:30 PM Monday, October 29, 2018

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Computed Tomography Inspection of Additive Manufactured Components at Sandia National Laboratories

Presenting author(s): Mr David G Moore

Co-Authors:

Room: N/A | 1:30 PM Monday, October 29, 2018

Additively manufactured (AM) components often exhibit lack of fusion and porosity without a clear understanding of how these discontinuities might degrade the mechanical performance of a part during service. This uncertainty is unacceptable for the design and manufacturing of most aerospace parts. This presentation provides a background into Sandia’s research efforts and explores the material characteristics of AlSi10Mg material using direct metal laser sintering (DMLS) power bed fusion process. Additionally, the identification of pores and porosity in AM materials using advanced computed tomography methods will be discussed. Examples of surface recognition, image segmentation and porosity characterization using computed tomography to assess inherent flaws within test samples will be presented. Sandia National Laboratories is a multi-mission laboratory managed and operated by National Technology and Engineering Solutions of Sandia, LLC., a wholly owned subsidiary of Honeywell International, Inc., for the U.S. Department of Energy’s National Nuclear Security Administration under contract DE-NA0003525.

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Design and Performance of an Accelerator-Based Thermal and Fast Neutron Imaging Facility

Presenting author(s): Mr Michael J Taylor

Co-Authors:

Room: N/A | 1:30 PM Monday, October 29, 2018

Phoenix LLC has developed, demonstrated, and deployed accelerator-based neutron generators for several applications that require neutron interrogation such as neutron radiography, neutron detector calibration, nuclear fuel quality assurance, and explosives and SNM detection, all of which are unique in their own technique of non-destructive testing. Of particular interest is neutron radiography, which is a very useful non-destructive imaging technique that aims to identify defects in materials where X-ray, ultrasound, Eddy-current testing, etc. will not suffice due to limiting densities, material composition and surface imperfections. Phoenix’s goal is to use its technology to acquire high-quality neutron radiographs, in a duration comparable to a traditional nuclear reactor, without the heavy regulatory burdens and high construction and operational costs. Phoenix has designed and evaluated the performance of a new neutron imaging facility that will provide capabilities for both thermal and fast neutron beamlines, primarily used for neutron imaging. The description of the facility, neutron moderators and collimators will be discussed in this presentation. Detectors will also be discussed in the context of digital neutron imaging and computed tomography. MCNP modeling data will be discussed that demonstrates the quality metrics of neutron radiographs regarding geometric unsharpness, collimation ratios, thermal and fast neutron fluxes and content, detection efficiency, as well as expected imaging time as it relates to imaging throughput.

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NDE Proficiency Demonstration

Presenting author(s): Mr Michael L Turnbow

Co-Authors:

Room: N/A | 2:00 PM Monday, October 29, 2018

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Inspection of Additive Manufactured (AM) parts using X-ray and Computed Tomography

Presenting author(s): Mr Lennart Schulenburg

Co-Authors:

Room: N/A | 2:00 PM Monday, October 29, 2018

Additive Manufacturing (AM) is a new and innovative technology compared to traditional techniques. Unfortunately, manufacturers till struggle to establish qualified inspection processes. This presentation will introduce the common defects in AM, inspection challenges and it will give insights how Computed Tomography could be a solution.

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New Handheld Technology for Carbon Determination in Steels and Stainless

Presenting author(s): Mr Donald D Sackett

Co-Authors: Mr David Day

Room: N/A | 2:00 PM Monday, October 29, 2018

SciAps, Inc. has introduced a breakthrough handheld technology for in-field analysis of carbon content in steels and stainless for positive material identification (PMI). The traditional approach – spark optical emission spectroscopy – (spark OES) requires a cart-mounted system plus large external tank of high purity argon gas. This makes testing in towers, racks, pipeline ditches or other difficult-to-access locations costly and time consuming. The new handheld technology utilizes laser induced breakdown spectroscopy (LIBS). The LIBS technology analyzes carbon and other alloying elements in stainless, steels and other alloys as well as carbon equivalents. The LIBS technique fires a pulsed laser to vaporize the material, stripping the electrons from the atoms to form a plasma. As the plasma cools, the electrons recombine with the atoms, and emit characteristic light in the UV, visible and infra-red. A spectrometer measures the light at various wavelengths and via an on-board calibration can quantitatively determine concentrations of C, Cr, Ni, Mo, Cu, V, Nb, Ti, Mn, Fe and other alloying elements. Because the laser beam is focused to < 100 um, a miniature argon source, located in the handle of the device, replaces the large argon tank used for spark OES. Data, results and test methods selected from 150 installations worldwide for carbon in stainless, steels and CE values will be presented. The LIBS technology is now also recognized in the 3rd edition of API Recommended Practice 578 and is now accepted by many pipeline companies and major refiners.

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NDE Engineering in the Natural Gas Industry

Presenting author(s): Mr Michael T Childers

Co-Authors: Dr John C Duke, Jr

Room: N/A | 2:30 PM Monday, October 29, 2018

While the Natural Gas Industry is vast, and with many different requirements of its Engineering departments, this presentation will focus on current and potential roles of an NDE Engineer, from Managing NDE QA/QC programs, to conducting Root cause analysis of material failures and incidents, researching and testing of current and emerging technologies for the Industry such as XRF, OES, CR, DR, PAUT, and Handheld 3D Pipe Metrology Scanners, as well as “traditional” methods of NDT, to conducting oversight of In-line Inspection (ILI) testing and selection of equipment used. We’ll also discuss the significance of the NDE Engineer actively participating in the writing of Industry Standards, and U.S. Code of Federal Regulation (CFR) referenced Standards.

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Red Herrings and Other Sundry Unidentified Flaws in NDE Engineering

Presenting author(s): Dr John C Duke, Jr

Co-Authors:

Room: N/A | 2:30 PM Monday, October 29, 2018

In that for the most part materials which engineers use for building stuff are not perfect. By appropriate design the engineer must achieve after fabrication consistent with that design a component, structure, or system that will when used as prescribed by the engineer (designer or design team) perform satisfactorily throughout the service life indicated by the engineer (designer or design team.) In addition to the imperfections present in the original materials, manufacturing of the design may also introduce imperfections, and service induced deterioration may introduce additional imperfections or cause imperfections already present to change. It is ultimately the responsibility of the engineer (designer, design team) to specify which imperfections must not be present during the service life to avoid failure. Recently the technical community is involved in an exercise to identify and catalog flaws in materials and components fabricated by the process generally labelled as “additive manufacturing,” AM. This presentation will make the case for why this exercise is insufficient for reliably performing nondestructive inspection of components manufactured by AM; an essential process to achieve the engineer’s goal. The argument is further generalized to any engineering design, despite the origin of the materials, which is meant to achieve and maintain structural integrity of critical components.

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Application of Non-Destructive Testing, ANSYS Analysis and Advanced Microstructural Characterization to Detect-Locate-Define and Simulate Defects in AHSS Steel Slabs

Presenting author(s): Ms Hsiang-Ling Juan

Co-Authors: Mr Zhanfang Wu, Mr Calixto Isaac Garcia

Room: N/A | 2:30 PM Monday, October 29, 2018

During continuously casting of steel slabs production, the presence of surface and internal defects takes place. These defects can include cracks, voids, coarse non-metallic inclusions and heavy local chemical and microstructural segregation. Many NDT techniques have been developed and used to assess the presence of these defects which have a specific “finger print” response to sound waves interaction. The factors responsible for these defects are often related to mechanical, thermal, or transformation stresses during the solidification process of the slabs. The high thermal stresses result from the difference in volume expansion or contraction behavior caused by the frequency of the temperature fluctuation during solidification. In order to study the effect of these temperature fluctuations a model of the thermal stress field using ANSYS simulation software was employed. In addition, to validate the model results a NDT-UT system was used to detect and localize the presence of the defects caused by thermal or transformation stresses. The results from the NDT-UT scanning were assessed with the image processing analysis to identify the size of the defects and their location in the slabs. These results were complemented with a systematic advanced microstructural characterization technique. The results of this study will be presented and discussed.

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Fluorescent Dye Penetrant Inspections Using Videoscopes

Presenting author(s): Mr Charles Janecka

Co-Authors:

Room: N/A | 3:30 PM Monday, October 29, 2018

Fluorescent dye penetrant inspection (DPI) is a well-established nondestructive testing technique that involves an aspect of visual inspection but offers increased flaw sensitivity. Recent advances in miniaturizing ultraviolet (UV) light sources have brought this ability to the world of remote visual inspection (RVI). One way to introduce UV light into an RVI application is by using a videoscope with an external light source and light guide. When the light guide is external to the insertion tube, however, it can impact the performance of the videoscope. Current offerings now have a UV light source that is housed inside the videoscope. This allows for much easier inspection of castings, internal aviation engines, automotive frames, and other RVI applications. The ASTM standards E1417 and E3022 apply to fluorescent dye penetrant inspections and UV light sources used, respectively. These standards were written and developed for fluorescent dye penetrant inspections done at a longer distance using a larger light source and the human eye as the imaging tool. While current videoscope offerings meet some of the requirements of these standards, they do not officially fall under their purview. This talk will go into more detail on how these standards impact RVI.

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Measurement of sub-millimeter flaws in thick layered materials with air-coupled ultrasound

Presenting author(s): Mr Tobias Gautzsch

Co-Authors: Mr Manuel Lucas, Mr Andreas Bodi, Mr Ralf Steinhausen, Mr Mario Kiel

Room: N/A | 3:30 PM Monday, October 29, 2018

In lightweight construction, a variety of semi-finished composite materials are used. The material properties of these materials are highly depended on the integrity of all adhesive and matrix structures. These can be impaired by impacts, production problems, physical stress or aging. For further processing, defective areas of the semi-finished products have to be identified to reduce the scrap rate. A fully non-contact air-coupled ultrasound (ACU) non-destructive system is implemented to measure production caused interlayer defects. The flaws can be air-bubbles, delamination or inclusions. The Ultrasound is emitted by a piezocomposite-sender into air and then transmitted through a plate made from the layered material. The ultrasound is detected on the opposing side of the plate by a piezocomposite receiver. To create the C-scan-image of the plate, an x-y-Scan is conducted and the received amplitude is displayed color-coded. In this study, a reference algorithm is presented that allows the detection of flaws less than a millimeter in diameter in material with up to 100mm thickness and 100 layers with frequencies as low as 50kHz. A comparison between the non-destructive air-coupled ultrasound testing results and a microsection will be shown and discussed.

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Mass Manufactured thin film transducers for high-resolution Scanning Acoustic Microscopy

Presenting author(s): Mr Ivan Shorokhov

Co-Authors:

Room: N/A | 3:30 PM Monday, October 29, 2018

The mass-manufacture of high-resolution ultrasound transducers remains a challenge. This work presents a scalable, additive manufacturing method for producing ultrasound transducers. The thin-film based sensors are easy to assemble, highly customizable, and provide large bandwidth at high frequency. A novel sensor material is deposited on to a flexible substrate using a reactive sputtering method and assembled into a tightly focused ultrasound transducer. A, B and C-mode data was recorded with a DPR 500 (JSR Electronics), 140V excitation, 0dB pre-amplifier gain, 5-300MHz bandwidth by mechanically scanning the transducer. The high-frequency thin-film transducer was used to produce images of several test objects. The results show that high-frequency probes based on thin-film technology could be used in acoustic microscopy for semiconductor and inspection applications. The probes were characterized found to have an average centre frequency of 45MHz, -20dB bandwidth of 86%, and -6dB bandwidth of 39%. The axial resolution of the probe was measured to be 50.9µm and the spatial resolution was 295µm corresponding to an f-number of 1.88.

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Impact of UV LED Technology to the Fluorescent Magnetic Particle Inspection (MPI) and Penetrant Inspection (FPI)

Presenting author(s): Mr Marc Breit

Co-Authors:

Room: N/A | 4:00 PM Monday, October 29, 2018

UV LED technology is about to completely substitute discharge bulb based UV sources in NDT. UV LED Technology offer possibilities to NDT the industry never had before. The new technology has a fundamental impact to the fluorescent inspection processes. This impact is bigger than any other development in this field since decades. UV LED Technology can sustainable improve the inspection process performance, but it is also able to critically affect the process adversely. This presentation will explain the physiology of the human vision, how the lamp characteristics affect the strain and performance of the inspector and how the inspection can be made better, easier and faster, while reducing the costs of the inspection.

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Foreign Object Identification within a Laminated Carbon Fiber Composite Using Pulse-Echo Ultrasonics

Presenting author(s): Mr Nathaniel Blackman

Co-Authors: Dr David Jack

Room: N/A | 4:00 PM Monday, October 29, 2018

Carbon fiber composites are becoming increasingly more popular in a wide variety of industries including aerospace, automotive, and athletics. During manufacturing foreign objects, such as loose peel ply, bagging materials, etc. may embed themselves between laminae causing localized weaknesses and stress risers. This has created a need to characterize these composite parts and identify defects in a non-destructive manner. This research improves upon current technologies for identifying foreign objects within carbon fiber composites. To simulate these foreign objects found within composite structures, we have placed PTFE inclusions between laminae during manufacturing. Inclusions such as PTFE are commonly used to simulate delaminations and defects with carbon fiber composites. Making use of a custom in-house ultrasonic immersion scanner, several techniques have been utilized to identify PTFE inclusions based off of the resulting c-scan data using custom MATLAB code and are presented in this work. The inclusions measure 0.002 in. (0.05 mm) in thickness, and results show that square inclusions as small as 0.04 in. (1mm) in width can be identified. In addition, the location within the laminate stack of the inclusions can be determined, and results for a 12 lamina composite have been investigated with a successful identification throughout the entire part. This work helps to advance the ability to determine the quality and safety of carbon fiber composites in a non-destructive manner by the identification of the depth and dimension of a foreign object.

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SAFT on its Way to Industrial Application: Pushing the Boundaries of the Ultrasonic Inspection by Ultrasonic Computed Tomography

Presenting author(s): Dr Johannes L Vrana

Co-Authors: Mr Karsten Schorner, Dr Hubert Mooshofer, Dr Karsten Kolk, Dr Alexander Zimmer

Room: N/A | 4:00 PM Monday, October 29, 2018

Critical large components, like Forgings, require intensive volumetric inspection to guarantee a sufficient lifetime. This is usually accomplished by manual or automated ultrasonic testing. We are reporting about a game changer in ultrasonic testing: Ultrasonic Computed Tomography uses analytics (i.e. a mathematical algorithm) to reconstruct the volume (In fact it uses a linearized diffraction tomographic approach for the solution of the inverse problem). This does not only allow to display indications spatially and visually correct in the 3D volume, but also improves the signal to noise ratio significantly, allowing an increase of sensitivity by up to an order of magnitude. The method is based on the Synthetic Aperture Focusing Technique (SAFT). The applied software is a brand-new implementation of SAFT with a strong focus for a large scale industrial application: the complete 2D as well as 3D reconstruction of ultrasonic inspections of heavy rotor forgings. This paper shows the working principle of the method along with the first industrial application experience. Ultrasonic Computed Tomography was also awarded by the Werner von Siemens Award as one of the Top 15 ingenuity programs.

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Proactive Ergonomics for MT Field Inspection Can Improve Your Bottom Line

Presenting author(s): Mr David Geis

Co-Authors:

Room: N/A | 4:30 PM Monday, October 29, 2018

The process of magnetic particle inspection is well known, and examination procedures have detailed specs and requirements. The equipment used for magnetization, especially yokes, have basically been the same for decades. So it’s generally accepted that magnetic particle inspection in the field is done in a certain way and takes a level of effort to complete. Across many industries, advances in ergonomic design have greatly improved working conditions, improving efficiency and reducing the risk of long-term injuries. There’s no reason why similar gains can’t be made with magnetic particle examination in the field. The basic sequence of an MT field inspection is the same with all applications. What changes from job to job is the accessibility of the area to be examined and the environmental conditions. These create risk factors that impact the safety and health of inspectors doing the work. Lifting heavy objects, irregular or unbalanced tools, awkward work positions, overhead work, extreme wrist or grasp deviations, and repetitive motions are all areas of concern. These risk factors lead to the development of musculoskeletal disorders (MSDs) that significantly impact the health and reliability of inspectors. There are many risk-reduction measures with a range of effectiveness. The most effective measure is elimination of the hazard itself. The next most effective is substitution: reducing the hazard by replacing the equipment used to do the job. Substituting a standard yoke with one that is specifically designed to minimize weight, wrist deviations, and grip force can significantly reduce the MSD risk factors involved with field examinations. Proactive reduction of MSD risk will impact an inspection company’s bottom line. Long term exposure to risk factors can lead to wrist and shoulder sprains or carpal tunnel syndrome. OSHA estimates the direct cost for these types of on-the-job injuries at $30,000 per incident, and indirect costs from workers compensation and increased insurance premiums can double that amount. While no single solution will eliminate all risks, moving to ergonomically-designed yokes to perform MT field inspections will significantly improve safety, employee wellness, and profitability.

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Using Excitation Modulation and Coding to Achieve Submillimeter Resolution In Materials Previously Impenetrable

Presenting author(s): Dr Chris Leskiw

Co-Authors:

Room: N/A | 4:30 PM Monday, October 29, 2018

The probability of detecting a discontinuity in a material is dependent upon the wavelength of the excitation used. The choice of wavelength becomes less straightforward when grains, pores, and fibers are similar in size to the discontinuity. Reducing the wavelength to less than one-half the size of the discontinuity guarantees that detection resolution will be sufficient, however, it also reduces sample penetration in heterogeneous materials. Furthermore, combining materials with unique favorable wavelengths complicates the choice for excitation wavelength. Measuring the thickness of a material behind a coating suffers when one wavelength is suitable for the coating and a different wavelength is suitable for the coated material. Here a solution is verified on multiple samples by relating detection resolution to excitation bandwidth. By maximizing the excitation’s bandwidth, and lowering the excitation’s center frequency, previously impenetrable heterogeneous materials were permeated while maintaining detection resolution. Excitation modulation was used to control the center frequency while excitation coding was used to overcome immense losses imposed by the material and transducer. For verification, the implementation was modeled both analytically and through computer simulation, and validated by physical lab testing with conventional transducers. Lab samples included, ½ inch thick carbon fiber, 1-inch thick fiberglass, 1-inch thick Acetal, 1¼ inch layered epoxy, 1¾ inch subsea coating on steel, and 3-inch thick high-density polyethylene (HDPE). Submillimeter resolution measurements were possible using conventional ultrasonic probes with 1.5 MHz and 500 kHz resonant frequencies while the center frequency delivered to the transducer was as low as 10kHz.

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Nontraditional Applications of XRF for Quality Assurance and Quality Control

Presenting author(s): Dr Michael Hull

Co-Authors:

Room: N/A | 4:30 PM Monday, October 29, 2018

X-ray fluorescence (XRF) is unique among nondestructive testing methods in that it primarily provides information on material composition rather than physical integrity. Historically, the principal use for XRF has been in positive material identification (PMI), most notably for applications involving alloy grade matching. But the scope of XRF applications is expanding, as nontraditional uses are identified in process control in manufacturing and production. Improvements in limits of detection, analytical precision, and increased element suites are enabling the exploration and discovery of applications for XRF in new sectors of inspection. Moreover, software improvements enhance ease of use as well as implementation in online processes and systems integration. Several case studies of nontraditional XRF applications will be highlighted in this paper, including: manufacturing, robotics, industrial geochemistry, and cloud-enablement. These case studies draw on examples from multiple industry segments, with the problem, data, and solution detailed for each. Principles for design and applications for solving novel problems as well as analytical precision and technological limitations will also be outlined.

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Utilizing Water Contact Angle Measurements to Control Surface Sensitive Industrial Processing

Presenting author(s): Ms Elizabeth Kidd

Co-Authors:

Room: N/A | 5:00 PM Monday, October 29, 2018

Validating chemical composition and properties of critical bond surfaces is crucial for controlling surface sensitive cleaning and preparation processes. Surface energy is a characteristic directly related to the composition of the uppermost few molecular layers and provides a metric of surface properties that is very sensitive to processing. Historically, surface energy has been probed by semi quantitative methods such as water break or dyne ink tests, however, these methods are subjective and can contaminate a test surface. The following presentation introduces an objective, non-destructive surface analysis technique which utilizes rapid water contact angle measurements to interrogate critical bond surfaces. Examples will be presented showing the use of this method for predicting bond performance and dye penetrant wettability and monitoring parts washer wash cycles.

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Phased Array Techniques and Defect Evaluation for Composites

Presenting author(s): Mr Philippe Rioux

Co-Authors:

Room: N/A | 5:00 PM Monday, October 29, 2018

The composite material is well known for its stiffness, corrosion resistance and its low density. This material can take complex shapes and in addition with its anisotropy makes UT inspection more challenging than conventional material such as steel. This scientific paper will address general issues like geometry, attenuation and the assessment methods. The respective last item will specifically evaluate different values like indication size and position and also amplitude based technique. Indeed, an indication inside composites can be described in length and also independently using different amplitude values like mean and attenuation. Besides evaluation, there are many technical/mechanical solutions that help and solve the complex geometries as follows: flexible probes, a curved array, immersion techniques and so on. The probe is also a game changer for an inspection configuration for many reasons; The frequency, probe elevation, pitch, flexibility and a proper wedge will be discussed. All the pros and cons will be brought up for each technique and assessment methods. The comparison between UT techniques will clarify and specify more solutions in order to properly characterize different type of flaws. In the last part, the paper truly explains why all these UT at its latest technologies is a preferred avenue to composite in NDT.

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Tool wear detection and quantitation by digital microscopy

Presenting author(s): Mr Marcel Lucas

Co-Authors:

Room: N/A | 5:00 PM Monday, October 29, 2018

Excessive tool wear can make workpiece dimensions become out of tolerance or even cause injury and equipment damage. Therefore, tool wear detection has a considerable economic impact by reducing the amount of scrapped parts, lost working days, and equipment downtime. Typically, tool wear is assessed qualitatively by scanning electron microscopy (SEM) which offers high spatial resolution and a large depth of field. However, due to the large SEM depth of field, accurate distance and height measurements remain a technical challenge. In contrast, the shallow depth of field of conventional optical microscopy makes the technique suitable for accurate distance measurements, but restricts its application to flat samples. In addition, the contrast in conventional bright-field microscopy images is generally low due to glare from metallic surfaces. This report will describe the benefits of digital microscopy and show how they overcome the disadvantages of conventional optical microscopy for the detection and quantitation of tool wear. In particular, a combination of bright- and dark-field illumination with high-dynamic-range imaging reduces glare significantly from the tool surfaces. Motorized focus control enables three-dimensional imaging of the cutting edge for accurate length, height and area measurements of worn sections.

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AEC Selection Process - Ad Hoc (closed)

Presenting author(s):

Co-Authors:

Room: Liberty B | 8:00 AM Tuesday, October 30, 2018

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Certification Management Council Open Meeting

Presenting author(s):

Co-Authors:

Room: Clear Lake | 9:00 AM Tuesday, October 30, 2018

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Certification Management Council (closed)

Presenting author(s):

Co-Authors:

Room: Clear Lake | 10:00 AM Tuesday, October 30, 2018

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Business & Finance (closed)

Presenting author(s):

Co-Authors:

Room: Liberty B | 9:00 AM Tuesday, October 30, 2018

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Penetrating Radiation

Presenting author(s):

Co-Authors:

Room: Liberty A | 9:00 AM Tuesday, October 30, 2018

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The Use of Pulse Compression in Ultrasonic Phased-Array Inspection: Code Selection and Optimization and Comparison with Single-Element Pulse Compression

Presenting author(s): Mr Muhammad Khalid Rizwan

Co-Authors: Mr Marco Ricci, Mr Stefano Laureti, Mr Luca Senni, Mr Pietro Burrascano

Room: N/A | 9:00 AM Tuesday, October 30, 2018

Pulse-echo is the most diffused NDT ultrasonic inspection method, for which almost all the standards have been developed. Pulse-echo is effective in most situations however, the application of multiple probes to cover the whole volume of large samples is not convenient and, secondly, system sensitivity is a critical issue in case of very large and/or highly attenuating materials. Phased-array ultrasonic inspection systems have been developed to overcome the cumbersome mechanical movement of UT transducers and electronically control the shape and position of the UT beam inside the material under inspection: a single phased-array probe can replace several UT probes and it could enhance the system sensitivity inside the material by focusing the beam. Moreover, together with advanced imaging algorithms this allows 3D imaging of the defects, hence results in better defect detection and characterization. At the same time, Pulse-compression ultrasonic inspection system has shown superior outcome than Pulse-echo in terms of signal-to-noise ratio (SNR). Recently, we have introduced the methods to single element probes together with numerically evaluated DGS/AVG analysis and obtained improved sensitivity and a better SNR. In this work we want to jointly exploit the pulse compression theory and the phased-array probes to address the system sensitivity in highly attenuating materials as well as a broaden inspection range in case of large samples. The development of numerically evaluated DGS/AVG analysis to phased-array probes will result in automatic defect detection and reduce the dimensions of minimum detectable defect (MDD) by adopting a multi-frequency approach.

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Inspection for HTHA Using TULA Transducers

Presenting author(s): Mr Timothy J Armitt

Co-Authors:

Room: N/A | 9:00 AM Tuesday, October 30, 2018

This presentation follows on from work developing a simple and more reliable way of imaging HTHA damage. Special hybrid transducers were prototyped and subsequently improved. The presentation will discuss concept to fruition and give examples of how a simple suite of TULA probes assist detection of extremely fine micro fissures in aging petrochemical plant.

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Vertical Electrical Impedance Scanner for Non-Destructive Concrete Bridge Deck Assessment without a Direct Rebar Connection

Presenting author(s): Mr Jeffrey Barton

Co-Authors: Mr Jared Baxter, Dr W Spencer Guthrie, Mr Brian Mazzeo

Room: N/A | 9:00 AM Tuesday, October 30, 2018

Corrosion of steel reinforcing bars is a major problem on bridge decks where chloride-based deicing salts are regularly applied. Vertical electrical impedance (VEI) measurements quantify the level of protection offered to rebar against chloride ion ingress. Like most other electrochemical assessment tools, VEI testing requires a connection to the rebar. Instead of a direct connection to the rebar at a fixed point, however, a semi-direct, low-impedance connection to the rebar can be made through placement of a sliding large-area electrode (LAE) on the surface of the concrete deck. Importantly, the LAE connection is completely non-destructive and can be rapidly deployed. In this work, a complete multi-channel VEI scanner and LAE were constructed and demonstrated in the field. For all of the test sections, the VEI measurements obtained using the LAE connection were comparable to those obtained using a tapped connection and consistent with visual observations of deterioration.

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How to Fully Utilize Your Phased Array System

Presenting author(s): Mr Jesse Groom

Co-Authors:

Room: N/A | 9:30 AM Tuesday, October 30, 2018

When asked to do 80 welds in a day a phased array inspector might feel a little over whelmed. But more over whelming than the inspection and field evaluation is the code compliant reporting and documentation of the 80 welds. Phased Array inspection is one of the most challenging NDE methods to date. The amount of information and documentation can slow down total inspection times and fatigue inspectors. But there is some relief in the fact that PAUT data is in a digital format and because of that we can automate processes. Over the years I and others have developed advanced tools and workarounds to PAUT software and operating system limitations. We will explore some of the advanced solutions and exploitations that can decrease inspection and reporting times while reducing errors as well as easing the burden of high production projects for inspectors. Solutions that we will explore will center around macros (mouse and software), Automated report generation, Automated filing systems, Weld tracking, and imports/ exports. Software and reporting Solutions will cover ultravision touch, ESbeam tool, Omni PC, but can be applied to others. Resources will be provided as well as the tools themselves and all are encouraged to copy, modify, use, or repurpose the databases, sheets, videos and other media that will be included. Come and see how to overcome the current limitations and get a vision of what is possible now and in the future with automation and integrated systems.

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gPIMS for Thickness Measurement and Guided Wave Screening of Subsea Pipelines

Presenting author(s): Mr Keith VineDr David Alleyne

Co-Authors: Dr Brian Pavlakovic, Mr Thomas Vogt

Room: N/A | 9:30 AM Tuesday, October 30, 2018

Guided Ultrasonics Ltd have been developing and selling gPIMS for corrosions monitoring of pipelines for more than 10 years. They are able to combine two measurements that give them significant advantages over other pipe condition monitoring sensors. They combine thickness measurements directly under the sensor with long range guided wave screening that enables pipe condition to be monitored over many 10s of meters. Thickness measurement under the sensor allows tracking of wall loss that may vary with circumferential position but is relatively constant along the pipe axis. Guided wave screening allows the distribution of corrosion along the pipe to be monitored so that corrosion affecting specific areas can be monitored without the need to know the precise location of corrosion as more than 100m of pipe can be monitored from a single gPIMS. Furthermore measurements of corrosion rate are made directly on the pipe rather than being inferred from measurement of a sample of material. Results from recent subsea installation will be presented to show real installation performance.

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Effect of Damaged Structural Members on Performance Degradation of a Vertical Lift Truss Bridge

Presenting author(s): Ms Erin S Bell

Co-Authors: Mr Vahid Shahsavari, Mr Milad Mehrkash

Room: N/A | 9:30 AM Tuesday, October 30, 2018

The presence of viable alternative load paths is potentially a vital property of redundant structures such as truss bridges as it permits redistribution of internal forces in case of failure or removal of main structural elements throughout the superstructure. The effects of members’ strength on the load carrying capacity of a gusset-less truss bridge, the Memorial Bridge in Portsmouth, NH, is investigated. A calibrated structural model of the bridge is subjected to variable loads as well as progressive damage levels to quantify the effects of damaged members on the bridge loading capacity. Multiple damage scenarios are simulated incrementally for each truss member by reducing its cross-sectional area. For each damage scenario, the maximum load carrying capacity of the bridge is defined as the maximum applying force for which the first structural member exceeds its ultimate compressive or tensile strength. To assess the safety and serviceability of the bridge, estimations are made by introducing a residual redundancy factor as the load carrying capacity ratio of the damaged and intact states of the bridge. While the redundancy factor of one implies the healthy condition of the bridge, the factor less than one signifies the presence of damage and loss of performance. This paper facilitates detection of the most critical structural components to degradation of the system load carrying capacity. It is shown that the less the redundancy factor is, the more likely the failure of the corresponding damaged truss member affects the bridge load carrying capacity and hastens its potential collapse.

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Conformable Wedge Phased Array Transducers for Inspecting Variable-Geometry or Complex Components

Presenting author(s): Mr Jerome Poguet

Co-Authors:

Room: N/A | 10:00 AM Tuesday, October 30, 2018

The transmission of ultrasound from the transducer into the inspected component is a determining factor in the performance of ultrasound inspections. Various coupling solutions exist to ensure this transmission. The most frequently used are: • Immersion of the component in water tank: This coupling presents the best acoustic performance (low attenuation, coupling homogeneity, no intermediate interface). However, the inspected parts need to be fully immersed and thus complex control systems are required. • Coupling by direct contact with a liquid couplant, or via a rigid wedge or a delay line with liquid couplant at the interfaces: This coupling requires simpler control systems for the inspection, but the homogeneity of the couplant film and attenuation in the wedges deteriorate the signal. The geometry of the inspected part can make the coupling more difficult to setup, particularly if the surface is complex or varies from one point to another. The problem becomes critical when the dimensions of the transducer are large in comparison with the local curvature of the interface. The use of transducers that are flexible, or that are fitted with a flexible wedge, improves the quality of the coupling for components with complex or variable geometry, and in some cases, makes it possible to do certain inspections that currently have no solution. This article presents the recent developments and results obtained in the context of transducers with flexible wedges, in particular: • Design options; • Flexible membranes development; • Mechanical interfaces development for multi-element transducers; • Mechanical supports development for manual or automated use; • Acoustic performance tests; • Wear resistance tests. These studies have demonstrated the contribution of flexible wedge transducers to various applications, with acoustic performances similar to that of immersion and easy implementation comparable to standard contact inspections, while remaining compatible with an industrial use. The detailed results will be presented, as well as the possibilities for the future developments of transducers with flexible wedges.

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Pipeline Mechanical Integrity Patterns from Large Ultrasound Data Populations: Performance Modeling, Prediction and Management

Presenting author(s): Dr Eugene B Silverman

Co-Authors:

Room: N/A | 10:00 AM Tuesday, October 30, 2018

Advances in the application of ultrasound testing (UT) for pipeline mechanical integrity monitoring are providing unique improvements in data quality, accuracy and reliability. Such improvements are inherent in emerging remote monitoring technologies. These technologies are helping the industry reduce data acquisition costs while providing much needed automated solutions to the challenges associated with the manual acquisition and management of pipeline UT data. Remote UT systems are finding their way into a wide variety of precision, non-invasive applications designed for continuous, real-time assessment of, for instance, internal and external pipeline corrosion. Additionally, non-invasive UT solutions are being applied to augment the monitoring of Cathodic Protection (CP) system performance while simultaneously validating the information generated by CP systems. One of the challenges associated with these developments is the generation of large populations of UT data that, when combined with pipeline environmental and operational parameters, can help identify pipeline integrity and performance patterns. This paper explores a multi-dimensional approach for integrating large populations of UT data generated by remote automated systems. Merging UT data with pipeline performance history, environmental geophysics and process parameters provides new opportunities for performance prediction and operational risk modeling. Specific examples of large data sets applied to modeling risk, projecting integrity performance and predicting future performance outcomes is presented. The use of machine learning tools typically found within the artificial intelligence community and applied to pipeline integrity management is discussed.

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Structural Inspections for Seismic Designed Structures

Presenting author(s): Mr Michael A Bobinchuck

Co-Authors:

Room: N/A | 10:00 AM Tuesday, October 30, 2018

Structures designed to meet Seismic requirements have increased inspection and testing requirements. From structures in a designated seismic area, to structures requiring enhanced design criteria due to terrorism potential, seismic structures are becoming more prevalent throughout the steel industry. This presentation will cover the various codes that are applicable to seismic structures, with emphasis on the two primary codes for the purpose of NDE inspections: AISC 341 and AWS D1.8. Seismic Force Resisting Systems (SFRS) have specific design criteria for the steel members themselves, but also specific welding requirements and the inspection requirements with those welds. AISC 341 covers design, fabrication, erection and inspection requirements, while AWS D1.8 covers the welding, inspection techniques and certifications required to weld and examine SFRS welds. Additionally, the differences between an SFRS weld and a Demand Critical Weld (DCW) will be discussed. All DCW welds are SFRS welds, not all SFRS welds are DCW. AISC 341 will be discussed, with a more thorough discussion of AWS D1.8, primarily the UT, VT and MT inspections specified in that code. From required practical UT tests to certify a technician to scan an SFRS weld, to specific techniques used to perform MT. There are detailed requirements for welder certifications to weld on SFRS welds and the techniques they must employ while welding DCW welds as well as the VT required to insure the requirements are met. Seismic Structures are a part of the Inspection Industry, and it is imperative they are correctly inspected to meet code requirements.

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Application of Advanced Focusing Techniques for Improved UT Inspection Capability

Presenting author(s): Mr Daniel Richard

Co-Authors: Mr Guy Maes

Room: N/A | 10:30 AM Tuesday, October 30, 2018

The introduction and adoption of portable phased array UT units has been a leap ahead for ultrasonic inspections of critical components in various industries. Due to the improved efficiency in preparation, acquisition, analysis & reporting of inspections, and to the availability of software tools that ensure code-compliance, phased array UT is now a mature and accepted technology. The next technological step involves Full Matrix Capture (FMC) and advanced focusing algorithms, e.g. Total Focusing Method (TFM). This new technology has been available for more than 10 years, but the time-consuming elementary FMC data storage has been a major hurdle for the industrial deployment of the technology. In recent years, “live” processing of FMC data has become technologically feasible: the drastic increase in processing power allows to perform the summing operations while the probe is moving over the component, and the resulting inspection speed becomes comparable to standard phased array UT. An important phase in the industrial adoption of these promising techniques is the experimental validation of the improvement in flaw detection and characterization capability that they can provide. This paper will demonstrate how advanced focusing techniques, implemented “live” on a high performance portable phased array UT system, can complement and improve the results of existing UT examination techniques. Examination data on various inspection configurations with realistic flaws (welds, corrosion, … ) will be shown and discussed. In addition, considerations about inspection resolution, coverage, and inspection speed will be presented.

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Inspection of High Temperature Line Welds Using ACFMT

Presenting author(s): Dr Michael C Smith

Co-Authors:

Room: N/A | 10:30 AM Tuesday, October 30, 2018

The ability to inspect welds at elevated temperature for fatigue cracking can provide significant cost savings by avoiding plant shut down. It also avoids any problems of crack closure which can occur when the structure is cooled down to ambient temperature. Conventional surface inspection methods such as WFMT or PT have limitations in their upper temperature range in the order of 120 – 140°F (48 - 60°C), although some specialist penetrants can be used up to 350°F (177°C) and some specialist dry magnetic powders are rated to 750°F (400°C). There is usually a reduction in sensitivity with these products compared with ambient temperature inspection. A gas process plant planned to install several weldolets onto an existing pipe run while the line was still in operation at 500°F (260°C) using the hot tap method. Prior to doing this, they needed to ensure that the target pipe surface was free from surface defects and that the welds created in the hot tap process were free from surface flaws. This article discusses how ACFMT probes were made to operate at the required temperature and how they were used to effectively ensure the integrity of the final hot tap welds without the need to implement an expensive line shutdown.

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Magnetic Rope Testing: Relevant Applications and Standards

Presenting author(s): Mr Alexander Mironenko

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Room: N/A | 10:30 AM Tuesday, October 30, 2018

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Methods Division

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Room: Liberty A | 11:00 AM Tuesday, October 30, 2018

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Professional Program Committee

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Room: Liberty A | 12:00 PM Tuesday, October 30, 2018

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Governance (closed)

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Room: Liberty B | 1:00 PM Tuesday, October 30, 2018

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T&E Full Council

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Room: Galveston | 1:00 PM Tuesday, October 30, 2018

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Honor & Awards Recognition (closed)

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Room: Liberty A | 2:00 PM Tuesday, October 30, 2018

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Research Council Program Committee (closed)

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Room: Brazoria | 10:00 AM Tuesday, October 30, 2018

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SOC Full Council

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Room: Galveston | 10:00 AM Tuesday, October 30, 2018

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Transformative Technologies Rapidly Advancing Phased-Array-Ultrasonic Inspection

Presenting author(s): Dr Deborah L Hopkins

Co-Authors: Dr Dominique Braconnier, Mr Gavin Dao, Mr Michel Brassard

Room: N/A | 1:00 PM Tuesday, October 30, 2018

Transformative Technologies Rapidly Advancing Phased-Array-Ultrasonic Inspection Significant technological advances in both hardware and software are transforming phased-array ultrasonic inspection. These advancements include greatly increased computer processing power, ultra-fast data-transfer rates and miniaturization of electronic components. Together, these technologies are allowing faster inspection rates and enabling new inspection techniques that are yielding higher-quality data at the same time that hardware costs are decreasing. Rapidly increasing processing power allows real-time signal processing and data visualization that can greatly improve resolution. High-resolution images in turn reduce the challenges of detection and sizing, in particular for difficult applications including welds, complex shapes and composite materials. Improved resolution not only eases the challenge of interpreting inspection results, but also fosters automated interpretation. High-resolution imaging does however result in large quantities of data that has proved problematic in the past. Utilizing fast data-transfer technology has solved that problem. Data transfer rates greater than 160 MB per second are now being realized on phased-array instruments using USB 3 technology. The fast transfer rates greatly improve data management and reporting for both inline and field applications. Miniaturization of electronic components allows more channels in less space. This in turn greatly reduces the form factor of instruments, which is particularly advantageous for increasing the functionality of portable devices typically used in service. At the same time, high data-transfer rates are enabling the use of sophisticated signal-processing algorithms on portable systems. Processing power and high data-transfer rates are not only greatly advancing signal and image processing, but also enabling the simultaneous use of multiple probes and sensors, as well as multiple inspection techniques. The additional information can greatly improve the speed and accuracy of defect characterization that is particularly important for inline manufacturing where speed and throughput are essential, while also providing more informative process feedback. A tremendous advantage of phased array technology is that it is highly customizable and well suited to acquiring data suitable for advanced signal-processing algorithms including total-focusing methods and surface-adaptive acquisition. The size, shape and spatial geometry of elements allow probes to be designed for flexibility so that the same probe can be used for a variety of inspections, or they can be highly optimized for a specific application. Industrial examples are used to illustrate how these technologies and advanced techniques are being used to improve phased-array inspection results. Examples include weld inspection, crack visualization and inspection of small radii in composite parts.

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New Technology for the Detection and Sizing of Carburization Damage in Plant Furnace Tubes

Presenting author(s): Mr Ankit Vajpayee

Co-Authors: Mr David E Russell

Room: N/A | 1:00 PM Tuesday, October 30, 2018

There are a variety of Fired Heaters (Coker furnaces, Catalytic reformers, Crude heaters, Vacuum heaters etc.) in industry today. Their operating parameters may be different but they all are prone to carburization damage in tubes over time. This damage makes the tubes more brittle and less able to contain pressure. A new, fast technology offered by Russell NDE Systems Inc. allows the detection and sizing of carburization without extensive preparation of the tube surface. An inspection procedure has been developed to detect, and later size the depth of carburization damage present without the requirement of any destructive tests. This paper talks about the inspection methodology and a case study.

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Flaw Detection Capabilities with Eddy Current Array Technology

Presenting author(s): Mr Jesse Herrin

Co-Authors:

Room: N/A | 1:00 PM Tuesday, October 30, 2018

Eddy current array (ECA) has enhanced the practice of flaw detection in multiple industries through expanded coverage areas, reduced inspection time, improved detectability, repeatability, and data recording. However, because ECA detectability is inversely proportional to scan speed, the signal-to-noise ratio (SNR) of today’s ECA techniques limits their ability to detect the very small flaws and loss of material that can occur in many inspections such as friction stir welds and multi-layer structures susceptible to corrosion and fatigue cracking. Minimum flaw size and required data density are the main factors affecting scan speed when using eddy current array. As speed increases, the SNR decreases, therefore the minimum flaw size becomes larger. Zetec introduces exceptional SNR in an eddy current array instrument, eliminating the need to sacrifice scan speed for superior flaw detectability.

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LabVIEW Toolkit for Setup, Acquisition, and Processing of Ultrasonic Data from Industrial-Grade Phased-Array Systems

Presenting author(s): Dr Marc Dubois

Co-Authors:

Room: N/A | 1:30 PM Tuesday, October 30, 2018

A phased-array ultrasonic software development toolkit called HaroUT™ and compatible with the graphical programming language LabVIEW from National Instruments was developed by HaroTek. This toolkit includes an ultrasonic delay calculator for single or dual, 1D or 2D phased-array probes. The ultrasonic delays can therefore be calculated for a large variety of configurations and uploaded directly from LabVIEW to industrial-grade phased-array systems. A-scans can then be acquired and processed within LabVIEW in real-time. This toolkit provides the ability to researchers in academia, government, or industrial labs to easily and rapidly customize acquisition and processing of data from phased-array systems, and for application engineers to prototype new inspection methods, improve current ones, or even directly develop using LabVIEW industrial inspection processes. The HaroUT toolkit can be downloaded for free from National Instruments LabVIEW Tools Network. This presentation will detail the toolkit architecture, and will include code examples and demonstrations of delay calculation and upload, and of data acquisition and processing.

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Practical and Economic Advantages of FMC/TFM

Presenting author(s): Mr Casper Wassink

Co-Authors:

Room: N/A | 1:30 PM Tuesday, October 30, 2018

Many equipment manufacturers now offer FMC/TFM as a technology on their advanced UT instruments. Standards development is ongoing in ASME, BINDT and IIW working groups. The number of successful application is growing. An overview will be presented on the status of standards development, as well as an overview of some the successful applications. Most literature on the technology has focussed on the ability to deliver better image quality. The focus of this paper is on showing how the improved images of FMC/TFM give practical advantages to NDT practitioners, and how these advantages solve engineering issues and add economic value. In other words, the paper describes some of the reasons for using FMC/TFM over other advanced UT techniques.

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Detection of localized wall loss with Pulsed Eddy Currents (PEC)

Presenting author(s): Dr Paul Crouzen

Co-Authors:

Room: N/A | 1:30 PM Tuesday, October 30, 2018

Pulsed Eddy Current Technique (PECT) is increasingly applied in the industry. PECT is known for its ability to detect Corrosion Under Insulation (CUI) without insulation removal, but there are many more inspection challenges the steel surface is not readily accessible and where PECT can add great value. For instance, PECT is beneficial for inspections through fireproofing, repair wraps, splash zone coatings, marine growth and concrete weight coatings. Since the publication of ISO 20669 in 2017, there has been a strong uptake in the use of PECT. Future growth is expected through inspection automation, since PECT is well suited for robotic deployment and use of probe arrays. The main drawback of PECT is its large 'foot print' over which the test specimen is examined. This makes PECT insensitive to localized wall loss and holes in the steel. History has shown that this limitation has sometimes been overlooked, leading to 'overselling' of the technology. The present paper aims to present a balanced view of the strength and weakness of PECT, based on over 20 years application experience in the oil & gas industry. To this end, a model is presented to predict the PECT response to localized wall loss. The outcome of the model calculations will be compared to both experimental data and calculations with a pipe line code. The model helps to quantify the sensitivity of PECT to localized wall loss and this make an informed decision on the suitability of PECT for practical applications.

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Binocular Focusing for Very High-Speed PAUT Integrations

Presenting author(s): Mr Francois Mainguy

Co-Authors:

Room: N/A | 2:00 PM Tuesday, October 30, 2018

Phased array inspections have reached very high scanning speeds in several applications, namely in aerospace composite testing and bar/tube testing. Typical linear scan firing sequence allows for firing rates above 20 kHz. The typical applications are using an aperture below 32 active channels, and multiplexed over 128 or 256 elements. This could be explained by the popularity of 32/128 phased array aparatus. When applications do require higher focusing capability, the choice of using 64/128 or 64/256 become more difficult to justify financially. And for very high mechanical speeds, using Full-Matrix Capture (FMC) and Advanced Imaging such as TFM and XFM are simply not possible with the current state-of-the-art. A binocular focusing solution is proposed to offer the potential of the imaging resolution of 64 active channels, while using 32/128 hardware.

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Towards Real Time Monitoring of Hybrid-Laser Gas-Metal-Arc Welding (HLGMAW) with Eddy Current Techniques

Presenting author(s): Dr Evgueni I Todorov

Co-Authors:

Room: N/A | 2:00 PM Tuesday, October 30, 2018

Hybrid-laser gas-metal-arc welding (HLGMAW) is a joining technology where two fusion processes are used to achieve high speed and high deposition rate reducing the cycle time and fabrication costs. It also enables faster welding of thicker materials where laser process alone would not be sufficient to provide required quality. The high welding speed requires deployment of robust welding monitoring tools and processes so that critical defects and nonconformities are detected and repaired earlier before significant nonconforming joint length is produced. An array eddy current (AEC) sensor and techniques were developed and demonstrated as part of a larger project in addition to other monitoring technologies such as phased array ultrasound, visual, and welding process parameter control. Unique AEC sensor was designed, optimized, and built following comprehensive state-of-the art review and extensive use of advanced computed modeling software. To enable building of representative computed models, electromagnetic properties (electrical conductivity and magnetic permeability) of selected material, stainless steel 316L, parent metal and weld were measured with model-based eddy current technique. The sensor was fabricated with features for air cooling and materials to withstand exposure to high temperature metal surface immediately after welding. Techniques were developed and demonstrated for examination of multiple passes. The first laser pass was examined with a single sensor element. The second gas-metal-arc pass was examined with all array elements. Trials conducted at INL demonstrated excellent sensor and technique performance during welding of the first and second passes at high temperature (following the torch) and room temperature (post-process examination) without touching the weld surface. All major flaws were detected. The sensor was also able to detect conditions such as laser power interruption, poor workmanship (e.g., lack of penetration), and possibly weld surface profile (lift off). EWI was awarded a patent for the sensor and examination technique.

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Phased Array Assisted Analysis Software for Weld Inspection

Presenting author(s): Mr Nicholas J BublitzMr J Mark Davis

Co-Authors: Mr Charles A Hansen

Room: N/A | 2:30 PM Tuesday, October 30, 2018

Encoded Phased Array Ultrasonics for weld inspection have gained popularity by providing among other benefits; increased probability of detection, enhanced sizing and characterization capabilities, time savings, and a permanent auditable record. Despite these benefits, there are still issues to overcome when utilizing Phased Array for weld inspections. For Asset Owner-Operators this includes a lack of a reliable way to confirm the quality of the Phased Array inspection services being provided to them without being trained to analyze the data themselves or paying an outside consultant to review the data. Service Providers struggle to retain certified personnel in a competitive market. A significant issue for both is data analysis time. While the speed of data acquisition has grown with faster instrument processors, the time to analyze data has not significantly changed throughout the years. Large amounts of Phased Array data can be collected quickly, but analysis and reporting usually take significantly longer. For the data analysts themselves, analyzing data also has shortcomings, especially with large files with multiple groups to manage. By focusing on real industry concerns identified by a Phased Array data verification company, a software program was developed to help make the data analysis process both easier and faster. The analysis process can be considerably expedited and improved upon by utilizing assisted analysis software that screens data for potential indications and quality issues while also providing additional valuable analysis tools for final disposition of the generated software results.

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Ultrasonic Readings through Coating

Presenting author(s): Mr Kenneth L Heaps

Co-Authors: Mr Joshua D Bell

Room: N/A | 2:30 PM Tuesday, October 30, 2018

This paper presents a new technique utilizing ultrasonic flaw detectors and dry film thickness gauges to determine substrate thickness on severely corroded and painted components, e.g., pipelines, tanks, pressure vessels. Variables are collected and input into a variation of the formula Distance=time x velocity to derive a coating and substrate reading acquired from the first back wall echo from an ultrasonic flaw detector. Ultrasonic thickness readings through coating have long been a challenge to industry. The issue is that most calibration blocks do not exhibit a coating while the component under ultrasonic examination does. ASME Section V Article 5 addresses this issue by stating “The finish on the scanning surface of the block shall be representative of the scanning surface finish on the material to be examined.” However, it is often problematical to match coating systems on calibration blocks to what exists on vessels, tanks and piping that have been in a facility for many years and painted several times. When wall loss measurements approach the boundaries of safe operating pressure the additional coating thickness provides a false sense of security that can create an unsafe environment. This paper will review current techniques for eliminating coating from ultrasonic thickness readings and provide an in depth review of the new technique.

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Advantages of Eddy Current Array Testing over Penetrant Testing for Inspecting Stainless Steel

Presenting author(s): Mr Terence Burke

Co-Authors:

Room: N/A | 2:30 PM Tuesday, October 30, 2018

For decades, penetrant testing (PT) has been the method of choice for inspecting the surface of stainless steel alloys. However, PT is ineffective on painted surfaces, adding costs that can be more expensive than the inspection itself. The recent technological advances in eddy current array (ECA) technology make it possible to inspect stainless steel alloys through paint and coatings. Using ECA to inspect through paint is an effective way to save time and reduce costs. The latest orthogonal-type ECA uses a flexible printed circuit board (PCB) and dedicated software to reduce the effect of liftoff, enabling a more uniform inspection on uneven surfaces. On stainless steel pressure vessels, for example, the geometric shape of the weld crown, the condition of the surface, and the presence of paint are factors that contribute to liftoff. When inspecting stainless steel alloys, Olympus’ flexible, orthogonal ECA probe conforms to the shape of the weld and, in combination with the software’s liftoff compensation algorithm, can help resolve this issue. The result is a cleaner signal and a faster, more reliable inspection. This new ECA solution benefits refineries and petrochemical and power plants.

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An Amplitude Modulation Imaging Approach for the Characterization of Cracks, In Complement to Standard Linear Imaging

Presenting author(s): Dr Dominique Braconnier

Co-Authors: Mr Ewen Carcreff, Mr Sylvain Haupert, Mr Guillaume Renaud

Room: N/A | 3:30 PM Tuesday, October 30, 2018

Ultrasonic imaging processes using linear approaches are essentially employed in non destructive evaluation for imaging, flaw detection and flaw sizing. Unfortunately, non-linear scatterers such as closed cracks are invisible to imaging approaches using the linear concept of acoustics. The detection of closed cracks is of great importance for the detection of flaw birth or to have a better estimation of the real flaw length. In this study, we present an ultrasonic technique called amplitude modulation imaging (AMI) for the imaging of non-linear scatterers. It consists of transmitting several conventional patterns having different power and to make a subtraction in order to get the non-linear residue. Experiments on a close crack created by thermal fatigue show that AMI gives a higher detection capability than linear ultrasound imaging. Different experimental cases show that linear and non-linear images give complementary information of flaws. The linear and the non-linear images reveal the opened and the closed parts, respectively. This is offering a new tool for a better characterization of cracks.

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The UT Technique: Benefits from Ultrasound Data Importation to Pipeline Assessment Software

Presenting author(s): Mr Steeves Roy

Co-Authors: Mr Mathieu Desmarais

Room: N/A | 3:30 PM Tuesday, October 30, 2018

In-service pipelines suffer from degradation over time which can become potential public threats if not evaluated and maintained properly. The list of potential anomalies on pipelines is extensive, but records have shown that metal loss is the major cause of pipeline incidents, accounting for more than a third of these. Asset owners face an important challenge in evaluating these defects accurately since it can occur on both external or internal surfaces of the pipeline. These being typically coated and then buried under a few feet of soil, a complete pipeline integrity assessment encompasses the use of a wide range of direct and indirect non-destructive measurement techniques (NDT) to characterize the material integrity and provide a trusted diagnostic. Direct measurement evaluations require considerable investments as pipelines must be unburied using expensive equipment, thus the evaluation techniques must be accurate and provide quick diagnostics. External wall loss is frequent on pipelines, and efforts have been put in the past to develop efficient techniques such as 3D external corrosion mapping. The dense and accurate data allow the extraction of external wall loss measurements as well as providing a quick diagnostic based on known standards. On the other hand, internal wall loss is not frequent on gas pipeline, but it is on liquid pipelines. In presence of internal corrosion, techniques such as phased array UT (PAUT) already offer sufficient resolution to provide an accurate characterization of the flaws, but its use is not widely spread, and it still lacks the potential of offering quick diagnostics based on known standard. Integration platforms are available on the market to close that loop. They fix many challenges by integrating a wide range of data coming from direct and indirect assessment and providing on-site diagnostics based on ASME B31G. This article intends to show the benefits in using an integration platform to provide on-site diagnostics for internal corrosion assessment on pipeline using phased array data. It will explain the context, the current solutions available through a case study and how they can overcome challenges caused using extensive evaluation techniques. Ref. : http://www.cbc.ca/news/business/cepa-2016-safety-report-1.3654640 https://cepa.com/en/ https://www.aboutpipelines.com/en/blog/you-asked-how-deep-are-pipelines-buried/ https://www.aboutpipelines.com/en/pipeline-101/why-spills-happen/

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Bio-Inspired Localization of Acoustic Emission Sources in Metallic Panels: A Deep Learning Approach

Presenting author(s): Mr Arvin Ebrahimkhanlou

Co-Authors: Dr Salvatore Salamone

Room: N/A | 3:30 PM Tuesday, October 30, 2018

Many aerospace and naval structures consist of plate-like panels that their defects, such as corrosion dents and fatigue cracks can be localized with acoustic emission (AE) techniques. However, such structural health monitoring techniques usually require a large number of sensors to localize the defects of an isotropic plate with geometric features, such as stiffeners. In addition, most such techniques are limited to the area sounded with sensors and cannot monitor the rest of the plate. These limitations are mainly due to ignoring the reverberations of acoustic waves that reflect from the boundaries and geometric features of the panels. Nevertheless, echolocating animals, such as bats, learn from and leverage these reverberations with only a few anatomical transducers: a mouth and two ears. Inspired by the nature, this study uses a deep-learning approach that learns from and leverages such reverberations to localize their sources with only a single sensor. This approach uses the information conveyed in the entire length of AE signals. This is in contrast with most traditional algorithms, which only use the first arrivals of the signals. In this way, the proposed approach implicitly uses the information pertaining to the edge reflections of Lamb waves as well as their dispersive characteristics. The architecture of the proposed deep learning model consists of a stack of autoencoders. In this architecture, each layer is first trained individually, and then all the layers are fine-tuned together. To train and test the performance of the proposed deep learning approach, Hsu-Nielsen pencil lead break tests were conducted on the surface and the edges of an aluminum plate that had a riveted stiffener. The localization results demonstrate the effectiveness of this approach. In addition, the results show that the proposed approach has no blind zone and can localize AE sources anywhere on the plate.

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Bounce Path Ultrasonic Attenuation and Attenuation Rate Tomographic Imaging of Microstructural Damage and Near Surface Defects

Presenting author(s): Mr Jonathan Lesage

Co-Authors: Mr Mohammad Marvasti

Room: N/A | 4:00 PM Tuesday, October 30, 2018

Available ultrasonic nondestructive methods for the characterization of microstructural damage, such as, High Temperature Hydrogen Attack (HTHA), Early Stage Creep and Micro-porosity, etc, although sometimes effective, are not always reliable or particularly quantitative in nature. This is due, in part to the fact that microstructural damage does not reflect ultrasound in a coherent manner, rather it scatters incident wave energy. Consequently, existing techniques based on detecting forward or back diffracted waves are only really capable of detecting damage once macroscopic cracking has been initiated. In the current paper, an alternative approach is presented, whereby a standard Full Matrix Capture (FMC) is collected and the specular reflections between individual element pairs are compared with respect to corresponding reflections collected from a clean reference sample. This process ultimately results in a Tomographic image, which gives a map of the increase in scattering attenuation with respect to the reference sample. First, the technique is validated on simulated A-Scans where distinct regions of microstructural damage are modeled by an increase in scattering attenuation. Here the proposed algorithm is shown to produce and image wherein the modeled damage is precisely positioned and sized. Next, a sample with clusters of micro-porosity (10 micron pore size) is imaged from both sides to show that the technique is capable of resolving the clusters whether they be top or bottom surface connected. Finally, the proposed algorithm is used to image a colony of stress corrosion cracks (SCC), from which the maximum crack depth in the colony is precisely estimated.

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Identification of Base Metal Cracking In Stainless Steel Lined High Temperature Reactors

Presenting author(s): Mr Stanley F Botten

Co-Authors:

Room: N/A | 4:00 PM Tuesday, October 30, 2018

INTRODUCTION. Many of the Reactors and Fracturing columns have a stainless-steel inner lining and the detection of both cracking in the liner and the base metal is important for the structural integrity of the vessel. Although this can be detected and evaluated using AUT and PAUT methods, the areas to be scanned can be very large and the vessels in question are always insulated and to do the UT scanning would require a complete cooldown and removal of all the insulation.

This paper discusses the use of Acoustic Emission (AE) to detect while the vessel is in operation and locate the area of concern and if base metal cracking is present. This is a case study of a successful AE test using waveguides and the follow-up verification of the areas of concern,

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In-Situ Detection of Fatigue Cracks by Acoustic Emission Techniques in Large Trailer Frames

Presenting author(s): Mr Rolf Klemm

Co-Authors: Mr Joao Pimentel, Mr Karl Ludwig Krieger, Mr Andree Irretier, Mr Munip Dalgic, Mr Hans-Werner Zoch

Room: N/A | 4:00 PM Tuesday, October 30, 2018

Acoustic emission testing is used in a broad range of applications (e.g. composites materials, aerospace or civil engineering). Lightweight structures in transportation increase the vehicles payload but also the risk of fatal fatigue failures of overloaded or long-term used trailer frames. An early detection of short fatigue failures would reduce maintenance time and costs and would simultaneously increase the transport safety. Large sections of complete truck trailer frames have been tested under overload conditions in long-term dynamic fatigue tests. Large regions of the structure, especially critical welded joints, have been investigated by a continuous recording with acoustic emission sensors (AE) attached to the structure. The results have shown that an accumulation of AE-events is already present before changes can be detected by strain gauges or a fatigue crack is macroscopically visible. Besides the real-time detection process of fatigue cracks, the work also describes the post-processing of the recorded signals. The amplitude of the acoustic emissions due to micro fractures is relatively small. Therefore, the validation and correlation of the AE-detections to fatigue cracks in the presence of strong background and machine noises is also discussed.

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Correct Sizing of Defects Smaller Than One Wavelength Using Ultrasonics

Presenting author(s): Dr Johannes L Vrana

Co-Authors: Mr Alexander Seeber, Dr Hubert Mooshofer, Mr Matthias Goldammer

Room: N/A | 4:30 PM Tuesday, October 30, 2018

In the field of ultrasonic testing there are two key questions: Which defects can be found and – in the case indications are found – do they restrict the use of the part? Regarding both questions, the prerequisite is a method for defect sizing. Over the last decades sizing methods were established like DAC (Distance Amplitude Correction) or DGS (Distance Gain Size) for defects smaller than the beam profile. Those methods utilize the echo amplitude and provide results which are proportional to the defect area. However, those approximations are only accurate for defects larger than one wavelength even that experience shows it can be applied for slightly smaller defects. With the progress of material technology and ultrasonic inspection the need to detect and size smaller defects is growing. Therefore, both for flat bottom holes and disc shaped reflectors the usability for small defects needs to be checked. In this publication, it is investigated how to correctly size small defects below one wavelength. Utilizing a grid-based simulation method the echo signals of cylinder and disc shaped reflectors of various sizes are calculated. By properly choosing the simulation method and grid it is ensured that all physical wave modes are included in the simulation and that the discretization error is negligible. A good correspondence between the simulation and classical defect sizing for defects larger than one wavelength is found. In the region between one quarter of a wavelength and one wavelength resonance effects are found, which result in classical defect sizing methods giving conservative results. In the region below one quarter of a wavelength DAC and classical DGS sizing leads to undersizing. This is discussed in detail and a formula for defect sizing is derived, which is applicable to small as well as large defects.

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On-Bead SAW Pipe Flaw Detection for Automated Ultrasonic Testing Machines

Presenting author(s): Mr Benedikt Kenfenheuer

Co-Authors:

Room: N/A | 4:30 PM Tuesday, October 30, 2018

The test for transverse flaws in line pipe welds is an integral part of all common standards and specifications for the automated, final production inspection of SAW pipes including (API 5L/ISO 3183, DNV-OS-F101, and Shell DEP 31.40.20.37). Common ultrasonic inspection procedures for SAW pipes have historically used an “X” (or “K”) probe configuration (with 4 probes) to test for the internal and external flaws separately near the surface of the pipe wall. The weld seam volume is typically not inspected at large wall thicknesses and a large associated seam width requires more than one probe fixture. The alternative to the “X” pattern is an On-bead probe configuration with 2 two conventional ultrasonic probes, which provide greater coverage of the weld-seam volume, but does not account for variations in weld seam geometries. In 2017, BHGE Inspection Technologies introduced the first Phased Array Wheel Probe in use at six major pipe mills world-wide. This device consists of a compliant polymer wheel filled with a liquid to enable transmission of the ultrasonic signal providing a simple and flexible configuration, independent of outer diameter weld geometry. The test results are optimized using the ultrasonic probe settings through adjustment of probe angles and by focusing. This first generation Phased Array Wheel Probe is suitable for wall-thicknesses to 50 mm. As described in patent EP3259587A1, BHGE Inspection Technologies has now developed a second generation Phased Array Wheel Probe with the following capabilities: • 128 Element Phased Array • Paint Brush method to inspect for transverse and oblique flaws in the SAW weld seam • Ultrasonic inspection of the entire weld width and the heat affected zone • Test of the entire weld seam volume • Easy compensation of seam offset, pipe curvature and geometric deviations independent of pipe geometry This new method combined with BHGE’s patented Paint Brush technology, results in same Signal to Noise Ratio as an X pattern inspection with 19 dB less amplification required referencing a flaw equivalent 1.6mm Through-Drilled Hole placed in between the middle and the edge of the weld). In summary, this new method, combined with Paint Brush technology and driven by BHGE’s USIP|xx ultrasonic instrument results in a test of the complete Weld-seam volume of SAW pipe, independent of pipe geometry, with the capability to detect oblique flaws.

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Acoustic Emission Evaluation of Corrosion Damage on Bottom Plate of Above-ground Storage Tanks

Presenting author(s): Mr Daisuke Kai

Co-Authors:

Room: N/A | 4:30 PM Tuesday, October 30, 2018

This paper describes AE (Acoustic Emission) diagnosis technique of corrosion damage on bottom plate of Above-ground storage tank. The corrosion damage diagnosis of above-ground storage tank before opening tank was requested in order to preventing sudden leakage and conducting economical maintenance. In Europe and the United States, Qualitative AE technique has been developed. This technique conduct diagnosis of bottom plate before opening tank by risk-based evaluation. In Japan, this technique could not apply due to difference concept regarding inspection (In Japan, quantitative evaluation of bottom plate thickness is required) In order to adjust AE technique to Japanese situation, Quantitative AE technique has been developed. In this technique, AE sensors is installed on shell and annular plate. This sensor layout could improve accuracy of evaluation of AE-source location (corrosion location). And, it also improve accuracy of noise reduction. As a result, the referential curve for prediction of the average maximum corrosion rate (quantitative corrosion rate) based on AE data was developed as quantitative evaluation technique without opening tank under plant operation. We consider this technique enables to plan of the maintenance before opening the tank determining the elements of repair work, preparing materials and establishing procedures for maintenance plan.

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High UT Precision Corrosion Monitoring Techniques

Presenting author(s): Mr Philippe Rioux

Co-Authors:

Room: N/A | 5:00 PM Tuesday, October 30, 2018

Corrosion has been monitored based on different techniques to ensure equipment reliability for many years now. In the last decade, Phased Array has grown to become a common method to achieve such an assessment. Lately, new ultrasonic image processing techniques such as Total Focusing Method (TFM), are available for such assessments generating a whole new potential. But more precisely, what is this new potential? Total Focusing has been known for high profiling accuracy and sizing capabilities, on the other hand, phased-array is generally faster and code compliant. This article will compare corrosion mapping results obtained using both Phased Array and the Total Focusing Method algorithm on a corrosion sample over time. Both data sets would be acquired during the same acquisition, using the same equipment through time for a reliable comparison. An exhaustive table of detailed measurements will compare both UT techniques and a discussion on the pros and cons of both techniques will follow.

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The Role of NDE in the API Codes and Standards

Presenting author(s): Mr Mark Carte

Co-Authors: Mr John T Reynolds

Room: N/A | 5:00 PM Tuesday, October 30, 2018

NDE techniques and methods have an increasingly important role in the application of the API Subcommittee on Inspection and Mechanical Integrity (SCIMI) Codes and Standards, without which we would not be able to ascertain the existing condition of our fixed equipment in the hydrocarbon process industry. One of the issues that I periodically come across in my asset integrity management reviews of operating sites is inappropriate or inadequate use of NDE technology for finding, characterizing and sizing of flaws and defects in fixed equipment. One of the most notable is misapplication of ultrasonic thickness testing (UTT). A lot of corrosion and damage mechanisms in hydrocarbon process equipment and piping are localized in nature. If localized corrosion is an issue in some of your equipment, it does little good to inspect with standard spot UTT. Your chance of finding highly localized corrosion with spot UTT are fairly limited unless you are using very close interval grid-pattern examination and even that doesn’t always work. When localized corrosion is an issue we need to be employing more profile and density radiography, scanning ultrasonics or a variety of other NDE techniques with which the NDE SME can assist. I’m aware of several major multi-million dollar asset losses (some in the hundreds of millions) that occurred when inspectors were using the wrong NDE technique for the damage mechanism of greatest concern. Case studies will be presented to support this issue. Inspection NDE technology has been advancing at a remarkable rate over the last two decades; so there are a number of specialized tools and services available in the commercial market for a wide variety of corrosion, cracking and other in-service degradation issues experienced in the hydrocarbon process industry. Some of the more advanced techniques and NDE services are not inexpensive. But if you think advanced NDE is expensive, you ought to see the price tag of a pipe blowout and ignition, large tank bottom leak, or vessel cracking or rupture from localized in-service damage that went undetected and created a substantial process safety incident, sometimes with fatalities. Numerous new and advancing NDE techniques will be mentioned that are now recognized in a variety of API SCIMI codes and standards.

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TBA - AE

Presenting author(s):

Co-Authors:

Room: N/A | 5:00 PM Tuesday, October 30, 2018

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Board of Directors

Presenting author(s):

Co-Authors:

Room: Harris | 8:00 AM Wednesday, October 31, 2018

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Board of Directors - Ceremonial Meeting

Presenting author(s):

Co-Authors:

Room: Harris | 12:30 PM Wednesday, October 31, 2018

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Next Generation NDT, NDT for Industry 4.0 and NDE for Everybody

Presenting author(s): Dr Norbert G Meyendorf

Co-Authors:

Room: N/A | 9:00 AM Wednesday, October 31, 2018

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Applied NDT: Practical Case Study on Plastic Piping System Quality Management

Presenting author(s): Mr Riccardo Barbone

Co-Authors:

Room: N/A | 9:00 AM Wednesday, October 31, 2018

The application of Ultrasonic PAUT / TOFD on Plastic Piping System is opening up a new business areas within Quality Management. We will review actual case studies, highlighting the existing state of the art in Pass / Fail criteria and the on-going technological challenges of live assessment and onsite field environments. The integration of rapidly evolving cloud, wireless and image recognition technologies will certainly play an important role in the near future.

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Challenges and Opportunities in the Advancement of NDT in Aerospace

Presenting author(s): Mr Venkata Ganesh Kota

Co-Authors:

Room: N/A | 9:00 AM Wednesday, October 31, 2018

The emergence of new testing devices and software has enabled greater technical mobility, there remain limitations to what NDT can offer. Eddy current testing, for example, despite being used for more than 50 years, remains a particularly complex process that needs specialist technicians. Its use is confined to use on conductive materials and has a limited depth of penetration. Meanwhile, liquid penetrants can only detect imperfections that are open to the surface, while testing on a rough surface will likely result in a false indication. , if equipment makers and customers work together some of these difficulties may be overcome. A closer relationship between NDT equipment manufacturers and their customers is needed to improve both the equipment and the way it can be used. However, the biggest challenge facing by NDT in Aerospace currently is the short supply of available expertise. As with all engineering disciplines at the moment, attracting the next generation of NDT inspectors has been difficult and is resulting in an ageing workforce. This was a highlighted in a 2012 survey by NDT recruitment firm PQNDT, which found that the average NDT inspector was 45 years old. work with connected inspection devices, believes that it is this type of technology and its synergy with younger, computer-savvy workers could help attract the next generation of NDT professionals. “When you think about how people use devices from a consumer standpoint, young people have a touch screen in their pocket as it’s what they grew up with. While concerns over skills persist, the NDT in Aerospace sector is one with great prospects.As the airline industry grows, so too, does the need for NDT to ensure aircraft reliability and safety. A report last year by researchers MarketsandMarkets, - “Nondestructive Testing Market by Technology – Global Trends & and Forecasts to 2014–2020”, estimates that the NDT industry will grow by 3.5 per cent annually up to 2020, increasing its overall value to $7bn .For sure plenty of opportunities for growth in the next five years.

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What about NDE 4.0, as we enter the 4th Industrial Revolution?

Presenting author(s): Dr Ripudaman Singh

Co-Authors:

Room: N/A | 9:30 AM Wednesday, October 31, 2018

Industry 4.0 is a name for the current trend of automation & data exchange in manufacturing technologies. It primarily includes cyber-physical systems, the Internet of things, cloud computing and cognitive computing. Different thought leaders have included other disruptive technologies. The case as it may be, the 4th Industrial Revolution is upon us. Just like the previous revolution, only the adaptive will survive this one. During the Spring 2018 conference, there was a conversation around NDE for Industry 4.0. Author would prefer to call upon his NDE industry colleagues to think about NDE 4.0 as we enter Industry 4.0. Broadly speaking, we could start with this rough definition, and evolve it collectively as a community. NDE 1.0 – No Instruments, No Amplification, primarily human senses. E.g. Visual, Leak detection, Hearing, Coin tap, Noise, Touch, smell, … NDE 2.0 – Instrumented, Analog Signal or Amplification, human operated. E.g Infrared, Ultrasonic, Eddy Current, Dye Penetrant, Magnetic Particle, Film Radiographic,… NDE 3.0 – Instrumented/computerized, Digital Systems and Signal Processing. e.g Acoustic Emission, Digital Radiography, Laser stereography, Thermography, … NDE 4.0 – Cyber Physical Inspection Systems from cradle to grave. Perhaps we could start with NDE 3.0 methods at the core, and bring in the Internet of Things (IOT) connectivity, Virtual/Augmented Reality (VR/AR), Robotics enabled access, artificial intelligence (AI) based decision support, Big Data Driven monitoring, … Author is convinced that the design principles of Industry 4.0 could easily form the basis for NDE 4.0. 1) Interoperability: The ability of instruments, sensors, devices, and people to connect and communicate with each other via IOT. 2) Information transparency: The ability of information systems to create a virtual reality (VR/AR) of the physical anomalies by enriching digital artifact models with sensor data. 3) Technical assistance: First, AI capability to support humans by aggregating & visualizing information comprehensively for making informed decisions. Second, robotics using cyber physical systems to support inspectors with tasks that are unpleasant, exhausting, or unsafe. 4) Decentralized decisions: The ability of automated cyber physical systems to make decisions on their own and perform tasks independently. Only in the case of exceptions, interferences, or conflicting goals, are tasks delegated to a higher-level inspector. Being an engineer by training and an innovation coach by practice, author would like to share his experience with emerging technologies, and also call for action with these two must ask questions: 1) What new technologies are possible that might provide NDE with significant performance advantage in terms of speed/cost/reliability of inspections, health monitoring and early warning systems, … 2) What new applications would Industry 4.0 bring, where traditional NDE techniques could work just fine?

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Use of Flexible Phased Array Technology for Corrosion Inspection on Pipe Elbows

Presenting author(s): Mr Simon Alain

Co-Authors:

Room: N/A | 9:30 AM Wednesday, October 31, 2018

Ultrasonic inspection of pipe elbows poses many challenges, the most significant of which are the various diameters that need to be covered and the fact that the surface shape changes from concave on the intrados to convex on the extrados. Owing to the complexity of this application, UT inspectors have opted to use small footprint conventional ultrasonic probes to perform spot check measurements. This process is slow, however, and the data output tends to be operator dependant. Furthermore, this method does not provide imaging, which limits the practicality of the results. Ultrasonic phased array enables large areas to be rapidly scanned at a high resolution, but standard linear phased array probes are rigid and cannot conform to changes in component geometry. Olympus has developed a solution to this problem—a new flexible ultrasonic phased array probe and dedicated scanner for high-resolution thickness mapping of pipe elbows. This innovative probe and scanner solution can provide a complete image of the entire pipe elbow, making it easier to diagnose the damage mechanism and determine the repair and/or maintenance strategy. These capabilities make it a useful tool not only in evaluating remaining operation life but also in helping prolong the extended life operation of pipes in plants. This paper illustrates how this new advanced ultrasonic phased array technology can contribute to pipe elbows inspection applications during maintenance, based on real cases.

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Predicting Bond Performance Through Non-Destructive Testing

Presenting author(s): Ms Brooke Campbell

Co-Authors: Ms Elizabeth Kidd

Room: N/A | 9:30 AM Wednesday, October 31, 2018

In aircraft manufacturing, the successful creation of adhesively bonded primary composite structures hinges on being able to control bond surfaces and predict bond reliability. Surface preparation is a critical aspect prior to bonding, requiring a non-destructive evaluation to verify and characterize acceptable composite surfaces. Traditional methods for evaluating composite surfaces, such as dyne inks and water break tests, can be subjective and destructive or otherwise inappropriate for a manufacturing environment. An alternative non-destructive method for determining surface energy is achieved via water contact angle measurements. X-Ray Photoelectron Spectroscopy (XPS) is a surface sensitive technique for characterizing the top 10 angstroms of a surface. Water contact angle measurements also probes this uppermost layer. Quantitative results, as determined by XPS, directly correlate with contact angle measurements and therefore also with surface energy. XPS verifies the use of water contact angle measurements to predict bond performance. This presentation will discuss the use of water contact angle measurements to reliably and objectively characterize composite surfaces with regard to surface preparation and predict adhesion in bond performance.

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Panel Discussion - NDT 4.0 Opportunities and Direction

Presenting author(s): Dr Ripudaman Singh

Co-Authors:

Room: N/A | 10:00 AM Wednesday, October 31, 2018

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Ultrasonic Testing Techniques for Detection and Sizing of Circumferential Cracking in Turbine Rotors

Presenting author(s): Dr Teodoro Leon-Salamanca

Co-Authors:

Room: N/A | 10:00 AM Wednesday, October 31, 2018

In the last 30 years, the fossil fuel power generation industry has seen tremendous changes in operations, management, and adaptation to meet the requirements of accommodating renewable energy generation. All these changes have affected the integrity of turbine and generator rotors in many ways, especially when a unit designed for base load operation is changed to peak load operation. One of the major problems stemming from these changes is the fact that steam turbine and generator rotors will develop fatigue cracking caused by thermal and mechanical operational stresses. Service induced defects start at the surface of the rotors, either peripheral outside diameter (OD) areas, inside diameter (ID) bore connected areas, dovetail areas under blading, areas under shrunk-on disks, etc. These service related defects will propagate perpendicular to the stress induced during service. For example, bore circumferential or hoop stress caused by thermal and mechanical stresses during startup and operation will induce axially oriented bore surface connected defects. Axial and bending stress applied on the shaft by thermal and mechanical forces will induce surface connected circumferentially oriented defects. A sample of 12 rotors that have develop circumferential cracking during this transition period were evaluated using ultrasonic testing (UT) techniques applied from the OD surface of the rotors and from the ID surface of the rotor central bore. The UT techniques include longitudinal and shear waves generated by conventional and phased array ultrasonic transducers. The group of 20 rotors include 7 HP-IP (High Pressure – Intermediate Pressure), 12 DFLP (Double Flow Low Pressure), and 1 generator rotor all having a central bore manufactured by various Original Equipment Manufacturers (OEMs). The circumferential cracking was sized from incipient at the OD surface to through wall to the ID bore surface and from the OD surface of the dovetails to up to 0.75 inches deep.

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Bond Strength Evaluation of Interfacially-Contaminated Adhesively Bonded Single Lap Joints using Ultrasonic Phase Measurements

Presenting author(s): Mr Harold Haldren

Co-Authors: Mr Daniel Perey, Mr Elliott K Cramer, Mr William T Yost, Mr Mool Gupta

Room: N/A | 10:00 AM Wednesday, October 31, 2018

Advancements in adhesive bonding applications in aerospace and automotive designs have increased the need for bond strength determination, as adhesive bonding is a preferred method of joining composite structures. While convention nondestructive evaluation (NDE) methods, such as ultrasound, have been used to detect gross bonding defects like voids and delaminations, they are insensitive to weak interfacial adhesion and cannot reliably detect “kissing” bonds. In this work, a phase-based ultrasonic method is used to study the resonance properties of acoustic reflections from adhesively-bonded single lap joints (SLJs) for the purpose of measuring interfacial bond strength. Six sets of joints of different strengths were fabricated using Al 6061-T651 adherents bonded together with FM 73 epoxy film adhesive. Bond strength was modified by spray-coating polydimethylsiloxane (PDMS) – a silicone-based contaminate – on one of the adherents prior to bonding. The concentration of PDMS in hexanes during the spray-coating process was changed to produce SLJs with varying interfacial bond strength. After bonding, the SLJs were ultrasonically evaluated with swept-frequency ultrasonic phase measurements around the acoustic resonance frequency of the bondline. The ultrasonic interactions with the adhesive/adherent interfaces is modelled by an interfacial spring system, where the spring constant is directly related to the interfacial bond strength. Interfacial stiffness constants extracted from the measured phase vs. frequency curves are used to predict interfacial bond strength. Predicted shear strengths are then correlated to actual bond strength measured via mechanical testing.

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Increasing the POD for Inspection of Oil Storage Tank Bottom Plates - API 650 / 620

Presenting author(s): Mr Alberto F Reyna

Co-Authors:

Room: N/A | 10:30 AM Wednesday, October 31, 2018

Actually, the internal inspection of Oil Storage bottom plates is developed with qualitative methods like MFL (Magnetic Flux Leakage) and LFET (Low Frequency Electromagnetic Testing), the results of these tests are presented in % lost of material, The POD of these test can be increased using the Phased Array device called "Wheel Probe" manufactured by Sonatest, this device lets the quantitatve test. High POD is reached using the MFL or LFET plus the "Wheel Probe - Phased Array". The inspection report includes C-Scan a B-Scan presentations

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Delamination Detection in Composites by Infrared Testing

Presenting author(s): Mr Gerardo Ramses Reyes Fuentes

Co-Authors:

Room: N/A | 10:30 AM Wednesday, October 31, 2018

The aerospace and automotive industries are increasingly incorporating the use of carbon fiber materials in structural components. During the manufacture and use of these carbon fiber materials, defects are induced in their structure, so it is important to detect them in time before they end in a catastrophe. One of the most damaging structural defects in carbon fiber laminates that often ends in a catastrophe are delaminations. It is necessary to develop an productive and non-invasive methodology to detect this defect. Analysis of heating and cooling on the surface with an infrared camera may be an option. During a warm-up and cooling cycle, a healthy zone and one with delaminations behave differently. A delaminated zone appears warmer than a healthy zone (Figure 1). This is because heat is best distributed to deeper layers in a healthy zone. The difference in the temperature gradient, during cooling of a healthy zone and one with defects, can be observed by a thermographic camera. Heat is supplied by a pulse (seconds) of light from a halogen lamp arrangement, followed by behavior analysis of the infrared radiation on the surface over cooling time (Figure 11). No physical contact with the component is necessary during the inspection, and the time between the pulse and the thermographic analysis is a few seconds, which makes this technique a simple, fast and non-invasive option to detect and delimit the area of damage. There are variables that affect the observation of infrared radiation in the inspection surface, such as the amount of heat supplied and the size / depth of the defect to be found. (Some others are atmospheric conditions, surface finish, and type of material). The sensitivity of the camera, and the image processing software, as well as a specific inspection procedure, acquire great importance in the sensitivity and detection range of the technique. In this study, we analyzed the infrared behavior on the surface of several artificially simulated delaminations on a carbon fiber board at different depths, to determine the efficiency and detection range of the technique. The objective was to develop an efficient, fast, simple and non-invasive methodology for the detection of delaminations in carbon fiber laminates.

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Non-Destructive Testing of Forgings on the Way to Industry 4.0

Presenting author(s): Dr Johannes L Vrana

Co-Authors: Dr Kai Kadau, Dr Christian Amann

Room: N/A | 1:00 PM Wednesday, October 31, 2018

Forgings, like most demanding components, are inspected with volumetric and surface detection NDT methods, either manually or using automated systems. The data collected during automated inspection gets processed and analyzed. Similarly, the inspector analyzes the information he sees during manual inspections. The results, like size and position of indications, and the inspection conditions, like sensitivity information and sound attenuation, are finally condensed into reports both for manual and automated inspections. Finally, those reports get printed, signed and archived. However, the data reported in most of those reports is a treasure which needs to be exploited by the NDE community. This paper reports which steps are necessary for the integration of non-destructive testing of forgings in industry 4.0 environments, including input parameters, data formats, data reconstruction, automated data processing, and big data evaluation. This will lead to a better utilization of the NDT data for example for data trending or probabilistic lifetime assessment methods. A preliminary analysis, including probability of detection, indication distribution, as well as detection sensitivity comparisons is presented.

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Inspecting Oil and Gas Assets Using Advanced NDE Technologies - EMAT, UT and MFL

Presenting author(s): Mr Aaron Huber

Co-Authors:

Room: N/A | 1:00 PM Wednesday, October 31, 2018

Aging gas and oil industry assets require regular inspection to ensure that operational integrity requirements of the industry. Some of these assets include gas and oil pipelines, gas compressor stations, and above ground storage tanks. There are several NDE sensors that each of advantages that are leveraged to inspect the different types of asset. This presentation will go through proven inspection techniques using robotic delivery systems equipped with EMAT, UT, and MFL sensors for each type of asset. For instance, gas pipeline operators want to avoid adding any liquid into piping systems making EMAT a proven resource because it does not require a liquid couplant. Diakont uses MFL and UT to inspect above-ground storage tanks while they are filled and in service because the liquid is already present. MFL provides good anomaly detection while UT provides detailed characterization of remaining metal thickness. This presentation will provide real-world case study examples of each inspection technology along with the benefits and limitations of each.

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Characterization of Honeycomb Core Damage on Rotorcraft Structures

Presenting author(s): Mr Edward Hohman

Co-Authors: Mr Robert J Barry

Room: N/A | 1:00 PM Wednesday, October 31, 2018

Composite sandwich structures containing honeycomb core come in a variety of shapes and sizes, and are used in a variety of aircraft. These structures may be used as flooring, side of body structures, and even in the after body of helicopter rotor blades. Regardless of intended use honeycomb core sandwich panels are subject to flaws and/or damage. The sources of induced core damage may vary between fabrication and field use, but the end result is usually the same…localized areas lacking in rigidity and stiffness. The simple act of detecting this anomalous condition is sometimes only half the battle. Understanding the origin, characteristics, and consequences of such anomalies add value in a multitude of ways. Crushed core in itself may not be a defective condition. Having the ability to quantify the severity of the crush may be the difference between scrap and continued service. Detection of honeycomb core damage is easily done using simple inspection methods when the core is sandwiched between thin composite laminate skins. But, the presence of this condition alone may not mean the part has been compromised from a structural standpoint. The structural consequences of a core crush condition may be dependent on several factors; the size of the area affected, the depth of the damage, the geometry of the structure affected, and the characteristics of the cell can all play a role. Having the ability to characterize different core conditions reliably and repeatedly can reduce scrap, reduce engineering review time, and may increase manufacturing throughput. This body of work describes some of the characteristics of composite honeycomb core that can influence the results of various inspection methods, and also compares various test methods and equipment that may be used to characterize and quantify such damage.

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Towards a Comprehensive Digital Twin for Autonomous Artifact Tracking

Presenting author(s): Mr Rafael Radkowski

Co-Authors: Mr Stephen Adams, Mr Peter Beling, Mr Stephen Holland

Room: N/A | 1:30 PM Wednesday, October 31, 2018

The paper will introduce our approach for autonomous artifact tracking using a digital twin with focus on manual inspection. One goal of our research is to automatically integrate manually collected thermography, ultrasonic, and eddy current data into a shape representation of the digital twin. All data is integrated semantically correct and registered to its related location on the product's surface. We utilize 3D machine vision for this process; it facilitates to automatically track the position and orientation of all essential components, which further enables data integration. A 3D visualization further allows an inspector to visually analyze all data that one collects over the product's lifetime, and to decide whether specific artifacts (data that does not meet the inspector's expectation) mandate further attention. We already presented prototypes addressing flash-thermography [1], and ultrasonic testing. The next step is autonomous artifact tracking using the digital twin, which means to identify and observe artifacts automatically and to inform an inspector when they become critical. Our approach embeds a virtual agent into this process. An agent can automatically learn from an inspector via reinforced learning and adopt the inspector's preferences and decisions. In contrast to other automatic flaw identification algorithms, it does not characterize the artifact. It recognizes patterns that the inspector deemed critical. Once trained, the agent can assess a more significant number of data samples, which eventually increases safety and quality. The paper will introduce the current work on inspection data integration as well as pitch our approach for autonomous artifact tracking.

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Pulsed Eddy Current Array: Improving the Productivity of Corrosion Under Insulation (CUI) Inspections

Presenting author(s): Ms Andreanne Potvin

Co-Authors: Dr Vincent Demers-Carpentier, Dr Maxime Rochette, Charles Tremblay, Mr Marco Michele Sisto

Room: N/A | 1:30 PM Wednesday, October 31, 2018

Pulsed Eddy Current (PEC) has been successfully deployed over the last decades for a variety of corrosion-related applications, most notably for Corrosion Under Insulation (CUI) inspections, Corrosion Under Fireproofing (CUF) and Flow Accelerated Corrosion (FAC). This technology has proven to be an efficient screening tool, allowing for detection of corrosion without having to remove coating or insulating material over typical pipes, tanks and vessels. Despite the success of the technique, one criticism to conventional PEC systems is that achievable productivity is relatively low, especially on thick walls and when an inspection with high spatial resolution is required. Recently, we developed a Pulsed Eddy Current Array (PECA) solution which greatly increase the productivity of the technique. The system is based on a novel pulsed eddy current probe featuring a linear array topology. The proposed probe design offers 18 inches (46 cm) of coverage in one single pass, improving the productivity of a pulsed eddy current inspection by a factor 4 to 10 compared to non-array solutions. The probe can be used on flat and curved surfaces with diameter down to 6 inches (15 cm). This is made possible by the non-rigid mechanical design of the probe, so that its main axis can be wrapped around a pipe or otherwise bent to follow the curvature of the inspected surface. Proper analysis of array raw data requires an adapted analysis algorithm, whose sizing performance on insulated components is presented in this paper along with examples of defect sizing maps of a typical insulated pipe. Recent results acquired in laboratory as well as in the field will be presented, analysed and discussed. The sizing and productivity performance of the latest improvements of PEC technique are compared to prior art technology, and benefits are discussed.

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Eddy Current Array for Aircraft Engine Component Inspection

Presenting author(s): Mr Terence Burke

Co-Authors:

Room: N/A | 1:30 PM Wednesday, October 31, 2018

Aircraft engine components experience elevated stresses and temperatures during operation. Consequently, to help ensure the safety of the public, the integrity of these components must be verified with reliable inspection methods. While the use of remote visual and dye penetrant inspection is widespread, the aircraft engine manufacturing and maintenance industries benefit from recent developments in magnetic methods, namely eddy current array. Eddy current testing (ECT) has long been considered the technique of choice to detect and size cracks on the surface of aircraft engine components. Unfortunately, inspections using single-coil eddy current probes can be slow, and the results can vary from operator to operator. In these and other respects, eddy current array (ECA) technology has advanced the technique significantly. Eddy current array enables full coverage of inspected zones while maintaining a high resolution. Portable eddy current flaw detectors enable the use of large arrays, and the image resulting from the software’s data processing helps the operator perform a reliable analysis. Probe holders and mechanical supports are continuously being developed to address the different applications of ECA for engines. Today, eddy current arrays are used by major aircraft engine manufacturers and maintenance companies to assess engine components, such as dovetails, blade attachments, and turbine discs. This presentation will review how eddy current array technology contributes to these inspections and the safety of the public.

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Improved Management of Thickness Survey Data Utilizing A Connected Instrument and Cloud Based Software

Presenting author(s): Mr Erich Henjes

Co-Authors: Mr Brian Johnston

Room: N/A | 2:00 PM Wednesday, October 31, 2018

Development of connected ultrasonic inspection instruments, along with mobile applications, and Cloud based software solutions are enabling rapid efficiency gains in the management of data collected during corrosion thickness surveys. Real time transfer of thickness data from the inspection device to applications via the internet allow for rapid data analysis and reporting, easy access to progress in inspection tasks, as well as substantial reduction or elimination of manual data processing. The efficiency gains in data management enabled by these technologies allow for more measurement points per inspector per day, reduction in error occurrences that can be introduced with manual processes, and continuous provisioning of new inspection points to the instrument and operator as sections of the overall job are completed and data is pushed to the Cloud or mobile application.

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Heat Exchanger Tubing Inspection: Revolutionizing Asset Integrity Management

Presenting author(s): Mr Olivier Lavoie

Co-Authors: Mr Joe Renaud, Ms Veronique Chayer

Room: N/A | 2:00 PM Wednesday, October 31, 2018

Pulling conventional tubing probes manually has been used to inspect all kinds of heat exchanger tubes for decades. It has proven to be an efficient way to detect a wide variety of defects. Some probe designs, however, face major technical limitations when it comes to sizing and detecting cracks. Manual inspection also has limitations in terms of speed (inconsistent acquisition and analysis times), data quality, and repeatability, without defect positioning. Imagine a solution that optimizes acquisition and analysis times, with the highest possible data resolution and defect position, monitored through time to yield optimal asset integrity management? This paper demonstrates how we can reach this goal by using software intelligence with optimal, encoded pull speeds of conventional and array technologies.

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A Novel Approach to Laser Ultrasound NDT for Aerospace and Automotive Applications

Presenting author(s): Dr Balthasar Fischer

Co-Authors: Mr Ryan Sommerhuber, Mr Nils Panzer, Mr Wolfgang Rohringer, Nico Lehmann

Room: N/A | 2:00 PM Wednesday, October 31, 2018

In conventional Laser Ultrasonic Testing (UT), the detection principle relies on the optical assessment of the vibration of the test object’s surface. We present a different approach: the vibrating surface of the test object is emitting a dispersive ultrasonic pressure wave into the adjacent air. This airborne acoustic wave is then detected by a novel laser-based microphone. The reason to access Laser UT with this alternative and novel approach is 1) to miniaturize the size of the testing head, 2) to become independent of the sample’s surface structure, and 3) to minimize cost. The excitation laser beam is delivered via optical fiber, so the sample can stay in a fixed position, while the excitation head is moving. The detection is based on assessing the acoustic waves, radiated into the air, by an optical microphone technology, where a miniaturized Fabry-Pérot etalon senses the air pressure via a change of local index of refraction. Since the detection laser is not directed onto the sample surface, but rather stays inside the detector head, the dependency on orientation and surface structure is reduced. Also, the compact-sized detector can reach into confined spaces in an automated production environment. Compared to optical detection methods traditionally used in Laser UT, the equipment pricing is very favorable. This is at the expense of depth resolution accuracy, since the propagation of ultrasound in air is physically limited to a few MHz only. While numerous measurements with carbon fiber reinforced polymer (CFRP) have been performed, the award-winning technology was also demonstrated on resistance spot welding joints between two steel plates in a car body construction context. A fiber-coupled excitation laser is used for the generation of the broadband acoustic pulse. The optical microphone is used as a detector, both in a single-sided and in a trough-transmission setup. By cross-scanning the welding joints with the probe, a two dimensional image (c-scan) can be obtained to evaluate the diameter of the resistance spot weld. Scan images will be presented and discussed.

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Cloud-Based Inspection Workflow Optimization using HHXRF — “The Inspection Is Not Over until the Paperwork Is Done”

Presenting author(s): Mr Alex Thurston

Co-Authors: Mr Peter Faulkner

Room: N/A | 2:30 PM Wednesday, October 31, 2018

Over the past 20 years, handheld X-ray fluorescence (HHXRF) has progressed from a luxury in inspection practices to an integral part of procedure. Features like accuracy and precision of results are no longer goals, they are expectations of performance. For a HHXRF instrument to benefit an inspection process, at a minimum, it must provide accuracy and precision combined with speed. Critical chemistry requirements once required lengthy test times to ensure applicable results. However, advances in handheld technology have increased the number of critical tests per minute, enabling operators to be more efficient. In a complete HHXRF inspection process, from preparation to final report submission, the most time-consuming element is often the report creation. In addition to on-site performance improvements, handheld instruments can now connect to the internet for data transfer, even in remote locations. With this new capability, handheld XRF provides added value, in terms of efficiency and time-savings, to any inspection process, helping to increase throughput and reduce instrument-related lag or processing time. This presentation covers the ways that advances in electronics and communication help expedite the transmission of reliable inspection reports from plant to management.

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Development of Compound Piping Calibration Blocks for Ultrasonic Weld Inspection

Presenting author(s): Mr Paul Holloway

Co-Authors: Mr Edward A Ginzel, Mr Andrew Robinson

Room: N/A | 2:30 PM Wednesday, October 31, 2018

Curved ASME piping calibration blocks are required for ultrasonic examination of welds on pipe of 20 inches (500 mm) diameter and less. These blocks must be sized within certain percentages of pipe diameter and nominal thickness, and many blocks are required to cover the range of common pipe sizes and schedules. As such, it is cost prohibitive for an NDT company to purchase a full set of blocks, and also impractical for a manufacturer to stock all sizes. Thus, the scenario arises when no compatible block is available, leading to expensive delays and frustrations for both the service provider and the customer. Using the guidance in ASME Section V (2017), the design of compound calibration blocks with stepped intervals on the inside diameter were investigated to reduce the total number of separate blocks required to cover common pipe sizes and schedules. During development, CIVA simulations were used to study the interaction of notches and the effect of multiple reflections off curved inner and outer pipe surfaces. Design features such as notch positions, section lengths and widths were controlled parametrically, driven by diameter and thickness, to optimize overall size. The culmination of this research resulted in a 3-block set, suitable for conventional and phased array ultrasound, that permits DAC/TCG calibration for pipes 4-inch to 18-inch diameter and virtually all pipe schedules. Advantages include reduced overall costs, drastically reduced weight totals, and simplified inventory control.

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Advancing Drone Use Beyond Visual Inspection: The Emergence of Contact-Based Nondestructive Testing (NDT) Utilizing Aerial Robotic Systems

Presenting author(s): Ms Jamie Branch »

Co-Authors:

Room: N/A | 3:30 PM Wednesday, October 31, 2018

Traditional nondestructive testing (NDT) techniques may require extensive manual testing by the inspector, often at vertical heights that must be accessed with equipment such as scaffolding, lifts, and ladders. While NDT inspection programs dramatically increase the safety and integrity of our equipment and infrastructure, access requirements in performing these inspections introduces risk to the inspector and the work site. Unmanned aerial vehicles (UAVs), or drones, can improve the safety and efficiency of performing NDT by completing the required measurements with workers remaining safely on the ground. This abstract addresses the current state of the technology, benefits, and limitations accompanied with utilizing aerial robotic systems as a viable means of NDT testing. Aerial robotics is an emerging technology that touches NDT sensors, such as an ultrasonic testing (UT) probe, to a wall surface using a hardened custom drone. This drone is equipped with an array of sensor systems, computer, and custom software to allow autonomous flight to contact surfaces for measurements. Autonomous flight describes the on-board computer’s capability to programmatically fly the aircraft to the material surface to achieve contact with the wall, without the assistance of a pilot. Using aerial robotics to perform contact-based inspections at height is a novel approach that has yet to be integrated into standard operations at industrial facilities. As the industry advances towards adopting drones/aerial robots as tools for inspection practices, it is critical to evaluate the associated performance and limitations.

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Improvements in the Ultrasonic Inspection Processes for the Power Generation Industry through Multiplexing

Presenting author(s): Mr David R Dechene

Co-Authors:

Room: N/A | 3:30 PM Wednesday, October 31, 2018

In telecommunications and computer networks, multiplexing (sometimes called muxing) is a method by which multiple analog or digital signals are combined into one signal over a shared medium. A device that performs the multiplexing is called a multiplexer (or MUX). In the world of ultrasonic testing, recent advances in computing power and ultrasonic instrument thru-put speeds has opened new opportunities for improved, and more efficient data acquisition. Both, automated and even manual inspections can benefit from multiplexing. Whether the aim is to acquire the same data, only quicker, or to acquire additional data within the same allotted time, multiplexing can be the answer. In power generation, multiplexing isn’t necessarily new. Most modern turbine rotor boresonic systems have been multiplexing through four or more fixed-angle ultrasonic probes for decades, and collecting two or more channels of TOFD data in a single pass on a high energy piping weld is another, albeit far more simplistic, form of multiplexing. What is new is that the complexity capacity for multiplexing has substantially increased. Instead sweeping through a few fixed angle beam probes, or collecting TOFD data in multiple amplitude channels, we can today multiplex multiple phased array probes; or collect TOFD data at various depth zones simultaneously, using the same probes; or perhaps collect two or more pulse-echo phased array channels, a pitch-catch phased array channel, and perhaps two or three TOFD channels, all concurrently, from the same two probes, using a single instrument. By doing so, all the data is curser linked together, and comparison between channels is a breeze. Example applications in the power generation industry include shrunk-on disks of large steam turbines susceptible to stress corrosion cracking at the disk bore/keyway regions. Radial-circumferential cracking of tangential-entry blade attachments may be another application, even high energy piping girth and long seam welds could benefit from multiplexing techniques. This presentation will explore the endless multiplexing opportunities available to NDE technicians today, evaluate equipment and computing requirements, and review real multiplexing data sets from a variety of power generation applications.

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Workflow for Automatic Turbine Blade Inspection on Optimized CT Volumes

Presenting author(s): Mr Peter Westenberger

Co-Authors:

Room: N/A | 3:30 PM Wednesday, October 31, 2018

In industries like aerospace where 100% testing is the standard, creating robust workflows that are suitable for automation can become challenging. We will present a workflow for automatic turbine blade inspection on optimized computed tomography (CT) data. The advancement process optimizes the spatial resolution of the CT volumes and it is based on established techniques from radiography. Furthermore the optimization provides error estimation of the extracted surface prior to the actual metrology. For the inspection workflow we will demonstrate robust and repeatable segmentation as well as sub-resolution precise surface extraction methods. Precise surface extraction is prerequisite for non-destructive standards like actual-nominal-comparison vs. CAD models, metrology or GD&T challenges. As a matter of fact turbine blade production comes with some unpredictable inspection tasks like reliable detection, segmentation, metrology, and analysis of air vents. We will demonstrate how to solve the issue of spatially unstable air vent drill patterns and how to do robust detection of foreign objects, or over-drills for each individual air vent. The inspection workflow, the optimization techniques, and the error estimation will help to build automatic inline inspection scenarios for the future.

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Using Drones and Digital Photogrammetry Techniques for Monitoring Vegetation and Topographical Changes in Southeast Texas

Presenting author(s): Dr Mahdi Safa

Co-Authors: Ms Alexandra Sokolova, Mr Kasra Ghahremani, Mr Lukas Moravits, Mr Micah Murdock, Mr Tyler Doiron

Room: N/A | 4:00 PM Wednesday, October 31, 2018

Environmentalists express concerns about the health of the planet and the vital role of wetlands on Earth. Sufficient knowledge of wetland changes is becoming more crucial as loss of wetland area increases. However, an ability to efficiently map and monitor the wetland topographies requires technology advancement. Producing high resolution and high quality digital elevation models (DEMs) requires substantial investments in personnel time, hardware, and software while increasing accessibility of three-dimensional imaging methods, such as digital photogrammetry. Further refinements have highly improved the method while preserving its convenience. This study investigates the use of unmanned aerial system (UAS) coupled with structure-from-motion (SfM) technology as a new methodology for monitoring vegetation and topographical changes in the southeast Texas Wetlands. This study aimed at maximizing the efficiency and accuracy of the data collection process for mapping the wetlands and other related applications. This paper serves as a summary and evaluation of various photogrammetric and data extraction techniques.

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High Resolution Flaw Detection with Ultrasonic Rotary Systems for Industrial Automotive Application

Presenting author(s): Mr Thomas Wurschig

Co-Authors: Mr Gabriele Blumentrath, Mr Stephan Schmitz

Room: N/A | 4:00 PM Wednesday, October 31, 2018

Common industrial standards for the tube inspection in automotive applications require the flaw detection of small inhomogeneities with a length of 2 mm and a maximum depth and width of 0.15 mm. Automated rotary ultrasonic testing machines (ROT) are well suited for the non-destructive testing due to their compactness and the absence of any radiation protection needed for the operation. In this paper, a ROT system equipped with conventional probes for the longitudinal and transverse flaw detection will be presented. Furthermore, it is possible to perform wall thickness and geometrical measurements such as the evaluation of the probe-to-probe eccentricity, the inner and outer diameter or the ovality. The testing machine is based on the powerful electronics platform USIP|xx, which is a modular system that can operate conventional probes, 1D array probes and 2D matrix arrays. It also features a detailed C-scan analysis of reference defects. The presented ROT system allows very short inspection cycles for the automated testing which are typically in the order of a few seconds only. Despite the high speed, there are short untested ends. Moreover, the inspection of subsequent tubes can be done in an end-to-end mode. The system is equipped with two different sets of probes with smaller and larger sound beam width, respectively. In this way it is possible to further increase the test speed by switching between the different options according to the applied standard. The changeover time for this switch is just in the order of a couple of minutes. Obtained results with the ROT systems deliver a reliable flaw detection (100%) with signal-to-noise ratios of 12dB and more even for the smallest defect sizes.

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NDT 4.0: Automated evaluation of X-ray images using AI and introduction of robotics

Presenting author(s): Mr Lennart Schulenburg

Co-Authors:

Room: N/A | 4:30 PM Wednesday, October 31, 2018

The innovations in the field of Artificial Intelligence (AI) and robotics allows new inspection concepts in the field of Digital Radiography (DR) and Computed Tomography (CT). This presentation and paper will focus on new developments, implementation examples and will provide a future outlook on the technology.

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In-service Corrosion Assessment for High Temperature Plant Components

Presenting author(s): Dr Tim Stevenson

Co-Authors: Mr Stuart Paul Kenny

Room: N/A | 4:30 PM Wednesday, October 31, 2018

In-service inspection is an essential part of integrity management for ageing assets. Condition monitoring locations (CMLs) are established across the plant and component wall thickness is obtained through ultrasonic spot measurements. These measurements are used to trend corrosion and erosion rates, assist with establishing fitness for service, and complete remaining life calculations. In addition to the cost of plant shutdown, deploying ultrasonic testing (UT) operators and providing suitable access with ropes and/or scaffolding, the accuracy of traditional manual ultrasonic testing methods requires a conservative tolerance to compensate for operator error and inherent inconsistency problems. At elevated and high-temperatures these tolerances are increased as operators lose confidence in the ability to compensate for velocity variances. One solution to these inaccuracies is to install sensors. These are often tied into monitoring systems which provide live data to control centres. Whilst the increased data is powerful, it can come at an initial high installation cost where required infrastructure such as wireless gateways are not already in place or where a facility is already committed to an inspection program. Some sites may have additional concerns around data security, battery life and qualification of the measurement without an authorised signatory. Here we propose using a novel hybrid approach, combining the benefits of installed sensors to overcome inaccuracies, and continuing to operate under the existing manual operator data collection model, to offer a lower entry cost alternative to autonomous continuous monitoring. Commercially available 3 MHz high-temperature UT transducers have been installed under the cladding on 12”, sch. 40 carbon steel steam pipework at a steel manufacturing plant, where the pipework is prone to corrosion whilst in-service, at temperatures exceeding 230 °C continuously. Installing the transducers fixes the variability in equipment as well as provides exact reproducibility for repeated thickness measurement location on the asset to better compare to previous readings. A-scans are collected by a UT operator using a Wand, inductively coupled (wireless near field communication, NFC) to a passive antenna, positioned on the insulation weatherproofing. In seconds, the operator can collect a UT thickness measurement and push the measurement to the cloud. Integrated calibration blocks in the transducer enable temperature compensation to be achieved by algorithm, and wall thickness trending is reported through the cloud to supervisors who can verify the analysis and result. For comparison, thickness measurement readings have been taken close-by during outages using the conventional manual UT inspection approach. From the site trials presented, this acquisition process allows much faster data collection, leading to more CML’s per operator per day, and a significant reduction in operator exposure to hazardous environments

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Macro-Etch Inspection Method in Aerospace Manufacturing

Presenting author(s): Mr Gee John Paw

Co-Authors:

Room: N/A | 4:30 PM Wednesday, October 31, 2018

This Presentation introduces Macro-Etch Inspection Method in Manufacturing of Aerospace parts. It discusses the dilemma classification for this Inspection Method, Is it a Chemical Processing or an NDT Inspection ? Presentation is more from an operations point of view, it introduces in brief Macro-Etching process, Visual Inspection, Knowledge and Skills requirements for a successful NDT. It discusses the concerns and benefits of this process. Examples of typical defects are shown and proposes benchmark Inspection method for this NDT.

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Simultaneous Increase of Productivity, Capacity and Quality in NDT of Engine Components

Presenting author(s): Mr Steve Saitowitz

Co-Authors:

Room: N/A | 5:00 PM Wednesday, October 31, 2018

The aerospace industry has experienced a rapid ramp up in production over the last few years and this ramp up will increase in the coming years. The demand for component supply especially engine disk and related hardware, is forcing manufactures to find ways to address the bottle necks created at the Ultrasonic NDT stage of production and also maintaining high standards of quality. Increasing capacity does not necessarily increase production or quality. Finding ways to get more out of available equipment and personnel does increase production and with the right technology improves quality. It is not enough to only automate. Automation does undoubtedly speed things up however the actual increase in production is still not at a level most manufacturers would like. Therefore technology that automates, allows for employees to be more productive, improves quality and increases capacity is the key to dealing with the expected ramp up in an expedient and cost saving manner. ScanMaster’s developments over the last 8 years has been focused in this direction achieving positive results and enormous production increases, higher quality inspections and tremendous cost savings. These developments include improving the following: • Transportability of part programs between multiple systems after importing geometry from existing CAD drawings • Automation of every day procedures such as transducer normalization, sensitivity calibrations and material attenuation • Automation of adaptation of sound beam entry on surfaces • High speed data collection and automatic file compression. • Easy transducer change mechanisms for multi-zone type inspections. • Solutions for automatic loading/unloading of the inspected parts • Sophisticated algorithms to auto evaluate captured data while working according to OEM procedures and specifications. • Rapid Data exchange solution • Unattended scanning: one operator running multi systems. These developments result in increased capacity, quality, and production, as well as reduced overhead costs.

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