NDTech Newsletter #9

Inspection and Measurements in Hostile Environments

The efforts of IMI's Process Instrumentation Section are focused on research and development of inspection and measurement systems to control the quality of materials and monitor fabrication processes directly on the production line.

Whether the equipment involves the use of lasers, ultrasonics, laser-ultrasonics or fiber optics, the development of these instrumental tools responds to a unique preoccupation: to be able to measure the various process parameters and properties of materials in environments which are often hostile, so that industry can fabricate high quality products and reduce its production costs.

Over the years, the specialists in this section have developed solid expertise in the field. When we consider all the techniques developed and used in plant for specific needs or those which have been commercialized, it is evident that the exploratory research efforts have yielded very worthwhile developments that benefit industry. Among these, the following several may be noted:

Thermal spray optical control system

Commercialized by Tecnar Automation of Saint-Hubert, the system involves the plasma spray method. This diagnostic apparatus, which uses infrared pyrometry coupled with an optical device and a camera, was designed to directly and continuously control the principal spray parameters during the coating operation, namely the temperature, speed and trajectory of the hot sprayed particles. These parameters were previously impossible to control due to the difficulty of performing such measurements in an industrial environment.

Laser Vision

Laser Vision, as its name implies, is a camera and laser vision system for electric arc welding operations. Fixed to a welding system, the apparatus makes it possible to track the work area profile and guide the positioning of the welding torch. Designed for use under difficult conditions inherent to welding, Laser Vision can carry out measurements at less than 2 cm from a source of intense heat and light. It also resists the molten metal droplet spray throughout several work shifts typical of welding conditions. This system has now been commercialized for more than 10 years by the MVS company of Ville St. Laurent, Quebec.

Acoustic wave guides

These systems provide reliable functioning of ultrasonic transducers in environments where their use would otherwise be impossible, such as in the vats containing molten metal and in the presence of high-powered electric arcs. These acoustic wave guides consist of a metal rod which has been coated with a material by thermal deposition. They notably serve to monitor the filling during polymer injection moulding and metal die casting. Tests carried out in collaboration with an instrumentation company have also demonstrated the effectiveness of this technique to perform measurements in molten light alloys such as aluminum and magnesium.

Laser-plasma spectroscopy

This advanced technology was developed to be able to analyze the composition of industrial materials in real time. Using a laser beam focused on a given material, it consists of producing a micro-plasma whose emission, analyzed by an optical spectrometer, provides information on the chemical composition of the material. This non-contact remote measurement technique can be applied in industrial environments that were heretofore inaccessible. In particular, it makes it possible to measure the composition of a molten metal directly in the foundry furnace, or ascertain the content of important elements of a mineral right in an underground mine tunnel.

Laser-ultrasonics

Laser-ultrasonic technology is one of the most effective ways to do precision measurements, directly on the production line, to assess the different parameters of a process and the properties of a material. The technology developed at IMI features two lasers, one to generate ultrasound and the other, coupled with an optical system (interferometer), to detect it. This nondestructive inspection and measurement technique can be applied to a great number of materials. Notably, it has been used to implant to gauge the wall-thickness profile of hot pierced tubes on the production line. Traditional techniques required a wait of possibly hours for the tubing to cool before this measurement could be carried out. The technology will also be used from aircraft to measure the thickness of the oil layer following a spill in the ocean.

These examples of technologies developed by the Process Instrumentation Section demonstrate IMI's prime objective in research and development: to serve the needs of industry.

For additional information, contact Jean F. Bussiere, Director, Process Instrumentation:

Phone: 515.641.5252

Email: jean.bussiere@nrc.ca

(1)This paper originally appeared in the CSNDT Journal, Sept/Oct. 1998.

Reprinted with their permission.

Stewart deWalle, Chairman of the Board of the NDE Institute of Canada, is pleased to announce, on behalf of the Board of Trustees, the appointment of Douglas J. Marshall as Managing Director of the NDE Institute of Canada, effective November 1, 1998.

Mr. Marshall has thirty years experience in nondestructive examination management, administration and human resources. Mr. Marshall brings extensive national and international involvement in nondestructive examination and predictive maintenance technologies to the NDE Institute. He has received many awards and acknowledgements for his outstanding dedication and contribution to the field of nondestructive examination. His efforts were most recently recognized by his peers with the presentation of the W.E. Havercroft Award in September of this year.

The NDE Institute has also provided comprehensive courses to organizations and NDE practitioners outside of Canada.

It has assisted foreign organizations and educational institutions, both private and government controlled, to set up NDE education and training to satisfy local industry needs and to establish national certification programs.

The Navy Joining Center (NJC) is working on a project to develop improved nondestructive evaluation (NDE) instrumentation for detecting kissing bonds in adhesive joints in naval structures.

Adhesive bonding is used in many Navy applications, most notably in the repair of aircraft. One problem with using adhesives is the occasional occurrence of "kissing" bonds, bonds in which surfaces display intimate mechanical contact but little or no molecular bonding.

The kissing bonds can escape detection under standard NDE inspection techniques because there is no noticeable separation of materials. Therefore, the Navy is looking for a more reliable means of detecting them in order to enhance reliability and reduce costs.

In order to develop such a technique, the NJC first needs to develop a methodology for consistently producing controlled kissing bonds in test samples just as they would occur in the actual manufacturing environment. The formation of kissing bonds is thought to be linked to contaminants on the repair surface such as fuel and hydraulic or de-icer fluids. The NJC is exploring commercially available inspection systems that can be used to measure surface contamination and determine when a surface is clean.

Once this is completed, test samples will be produced and then mechanically tested to determine their bond strength. Test samples that accurately simulate kissing bonds found in the manufacturing environment will be used to evaluate candidate NDE instruments on their ability to detect kissing bonds.

The instrumentation developed must satisfy several criteria including portability, ease of use, and the ability to conduct close-to-the-edge inspection. Several techniques will be investigated including variations of ultrasonic testing.

For more information, contact:

Harvey Castner at the NJC

Phone: 614.688.5063

Email: harvey_castner@ewi.org

Martin Jones at EWI

Phone: 614.688.5146

Email: martin_jones@ewi.org

New NTIAC Publications

NTIAC is nearing completion of a series of new special publications which will be available for purchase from NTIAC in January 1999. These publications, which include state-of-the-art reports and technology assessments, cover a variety of technical topics of current interest in the area of NDE. Titles of these publications along with authors follows:

State-of-the-Art Reports

NTIAC-SR-98-01 Neutron Radiography by Harold Berger and Frank Iddings

NTIAC-SR-98-02 Heat Damage in Graphite Epoxy Composites: Degradation, Measurement and Detection by George Matzkanin and George Hansen

NTIAC-SR-98-03 NDE of Hidden Corrosion by George Matzkanin and Jacob Easter

NTIAC-SR-98-04 NDE of Cracks in Aircraft by Jacob Easter and George Matzkanin

Technology Assessments

NTIAC-TA-98-01 Laser Ultrasonics by James Wagner and James Spicer

NTIAC-TA-98-02 NDE for Process Control of Polymer Matrix Composites by Tom Yolken

NTIAC-TA-98-03 Micro-Electromechanical Systems (MEMS) for NDE of Navy Aircraft by Russell Austin and George Matzkanin

NTIAC-TA-98-04 Magnetic Particle Inspection: Capabilities and Problems by Lydon Swartzendruber

It is anticipated that these publications will be sold for approximately $50 to $80 each. Additional details on pricing and descriptions of con tents will be provided in the next issue of the NTIAC Newsletter and by separate mailing. A 10% discount will be given for all orders received before January 1, 1999. Reserve your copies today.

For more information on these new publications, please contact:

Shelly Clark, NTIAC

Phone: 800.684.2239

Fax: 512.263.3530

Email: clark@ntiac.com

New test panels to meet ASTM E-1417 requirements

Under the new regime of ASTM E-1417 penetrant users must regularly test the performance of in-use penetrant by comparing it to the performance of unused penetrant. This is an extension of the Mil-Std-6866 requirement for daily system checks using a device such as a "TAM Panel." Only now, a comparison must be made between in-use and unused penetrant.

ASTM E-1417 allows for making the comparison to photographs, to laboratory records, or to equivalent known defect standards, "KDS's."

The main problem with photographs is that fluorescent indications do not photograph well, and comparing a non-fluorescing photo image to real world, fluorescing indications is difficult at best. Similarly, comparing real world indications to verbal or numerical data is unreliable. The best choice for comparing penetrant performance is to use two equivalent test pieces and make side-by-side comparisons.

One way to perform the comparison tests might be to use two TAM Panels, such as our PSM-5 Panels, processing each with a different penetrant and comparing the results. However, this is not satisfactory for several technical reasons, the principal one being that their manufacturing process precludes TAM Panels from being sufficiently matched twins to render side-by-side comparisons reliable.

To overcome this problem, Sherwin Incorporated has perfected a process for making two panels from single pieces of metal. The panels correctly may be called "twins."

The panels, known as "Twin KDS Panels™," differ from TAM Panels in several important ways. Twin panels are produced from a single metal sheet so they are matched as to surface plating, roughness, and cracks. In addition, the plating thickness is much thinner than that of TAM Panels, making induced cracks more sensitive to process anomalies. Moreover, using a patent-pending process, cracks are produced in pairs, and their size is controlled.

At the same time, Twin KDS Panels are rugged and economical. They withstand daily processing, and would not be considered "delicate laboratory tools."

Penetrant users searching for the best way to comply with the ASTM E-1417 for regular system checks should consider using Twin KDS Panels.

Technical literature and reprints are available by contacting Sherwin Incorporated.

From Sherwin, Inc. 5530 Borwick Ave., South Gate, CA 90280

*Abstracted from "Penetrant Progress" newsletter.

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The Ultrasonic Testing of Concrete-Abstracts of Technical Papers

1) Use of stress waves for determining the depth of surface-opening cracks in concrete structures - Lin, Y.C.; Su, W.C.

ACI Materials Journal, Vol. 93, No. 5, pp. 494-505 (1996)

2) Ultrasonic evaluation of damage in concrete bridge deck pavements - Peterson, M.L.; Landis, E.; Achenback, J.D.

Review of Progress in Quantitative Nondestructive Evaluation, Vol. 14B. Proceedings of the 21st Symposium on Quantitative Nondestructive Evaluation, Snowmass Village, Colorado (United States), 31 Jul. - 5 Aug. 1994. pp. 2169-2176. Edited by D.O. Thompson and D.E. Chimenti. Plenum Press (1995) ISBN 0306450623

3) Detection of deterioration within and beneath concrete pavements with sonic and ultrasonic surface waves - Nazarian, S.

Proceedings of Nondestructive Evaluation of Civil Structures and Materials Conference, Boulder, Colorado (United States), 15-17 Oct. 1990. pp. 371-391. PB94-121720. Edited by B.A. Suprenant, S. Sture, J.L. Noland and M.P. Schuller. National Technical Information Service (1990)

4) Delamination detection in concrete bridge decks using nondestructive test method - Sabnis, G.M.; Kelishami, R.; Millstein, L.

Proceedings of Nondestructive Evaluation of Civil Structures and Materials Conference, Boulder, Colorado (United States), 15-17 Oct. 1990. pp. 371-391. PB94-121720. Edited by B.A. Suprenant, S. Sture, J.L. Noland and M.P. Schuller. National Technical Information Service (1990)

5) Inspection of concrete by ultrasonic pulse-echo-technique - Hillger, W.

6th European Conference on Nondestructive Testing, Nice (France), 24-28 Oct. 1994. Vol. 2, pp. 1159-1163. ECNDT (1994)

6) Impact-echo for flaw detection in concrete highway structures - Poston, R.W.

Structural Materials Technology, Atlantic City, New Jersey (United States), 23-25 Feb. 1994, pp. 231-235. Edited by R.J. Scancella and M.E. Callahan. Technomic Publishing Co., Inc. (1994) ISBN 1-56676-141-7

7) Nondestructive testing of older concrete bridges: a case history of the SEPTA Manayunk bridge - Sack, D.A.; Olson, L.D.; Kline, T.R.; Yates, G.A.

9th Annual International Bridge Conference, Pittsburgh, Pennsylvania (United States), 15-17 Jun. 1992. pp. 405-413. Engineers Society of Western Pennsylvania (1992)

8) Nondestructive strength assessment of concrete-based structures - Stewart, A.H.; Goodman, J.R.

Engineering Data Management, Inc., Fort Collins, Colorado (United States), PB94-145851/GAR, 80 pp. (Jul. 1987)

9) Ultrasonic inspection of concrete structures to detect the condition of embedded steel components - Damaj, W.T.

Ph.D Thesis, University of Manchester (UK), Department of Civil and Structural Engineering, 423 pp. (Jun. 1990)

10) Advanced NDT methods for concrete structures - Sack, D.A.; Olson, L.D.

International Conference on Nondestructive Testing of Concrete in the Infrastructure, Dearborn, Michigan (United States), 9-11 Jun. 1993. pp. 353-369. Society for Experimental Mechanics, Inc., (1993) ISBN 10912053429

11) Recent developments in inspection techniques for corrosion damaged concrete steel structures - John, G.; Hladky, K.; Gaydecki, P.; Dawson, J.

Corrosion Forms and Control for Infrastructure. Edited by V. Chaker, pp. 246-257. ASTM. STP 1137 (1992)

12) Impacts as a source of acoustic pulse-echo energy for nondestructive testing of concrete structures - Alexander, A.M.

Army Engineer Waterways Experiment station, Vicksburg, Mississippi (United States), AD-A264 368/2/GAR, 86 pp. (Apr. 1993)

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