Session: 20-01: Online NDE techniques for smart manufacturing

Paper Number: 98283

98283 - In-Process Phased Array Ultrasonic Inspection During Fusion Welding 

The challenges inherent in manufacturing high-integrity complex components, such as those found in the nuclear and defence sectors using fusion welding techniques are significant. Traditionally, the welding and inspection of such welds are distinctly separate manufacturing processes, which ultimately limits productivity and throughput along with increasing re-work if defects are detected post-build. The Advanced Welding Equipment System Inspection and Monitoring (AWESIM) project introduces ultrasonic phased array inspection directly during welding to allow detection of imperfections and flaws as they occur, thus reducing rework, repair and delivering high-quality welds right, first time.

High-temperature dry-coupled Phased Array Ultrasonic Testing (PAUT) is introduced directly during Gas Tungsten Inert Welding (GTAW) deposition. A novel high-temperature automated roller probe for weld inspection is introduced and presented alongside imaging algorithms to compensate for the effect of negative process parameters such as temperature gradients, partially-filled grooves and Electromagnetic Noise Interference (EMI).

The results of this work are presented on sub-scale carbon steel plate and pipe demonstrators with both intentionally controlled (1.0 mm ID Tungsten Tubes) and unintentional defects (Lack of Fusion, Porosity). The SNR and sensitivity of the imaging and inspection system is measured, evaluated and quantified offering impact benefits such as reduced rework, schedule slippage and cost.

Presenting Author: Charles Macleod University of Strathclyde