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Automated Robotic Systems for Nondestructive Testing of Aerospace Composite Structures 航空复合材料结构无损检测的自动化机器人系统
IF 0.6 4区 材料科学 Q4 MATERIALS SCIENCE, CHARACTERIZATION & TESTING Pub Date : 2021-07-01 DOI: 10.32548/2021.ME-04224
Fetzer Barry
Automated robotic systems are becoming prevalent in many aerospace manufacturing applications, such as laser ablation, sanding, drilling, final assembly, and painting. There are significant advantages to using automated robotic systems for inspection purposes as well: versatility, speed, and repeatability, to name a few. This paper explores using an automated robotic system for the nondestructive testing (NDT) of composite parts. It has a focus on phased array ultrasonic testing (PAUT) but highlights modularity principles in the system that are not coupled to a single inspection method. Because of the articulation inherent in multi-axis robots, inspections of contoured structures become straightforward if the system modules are designed correctly. Examples of such modules, and their advantages when interfaced to an automated robotic system, are included in this paper. It is the author’s intent to show how these system modules might maximize robot capabilities for a broad range of aerospace inspections while keeping a simplistic design that is modular, fast, and straightforward to use. When compared to other aerospace manufacturing processes already using automated robotic systems, the use of robots for NDT seems not only prudent but a favorable goal. This paper offers practical building blocks for achieving this goal.
自动化机器人系统在许多航空航天制造应用中变得越来越普遍,例如激光烧蚀、打磨、钻孔、最终装配和涂装。使用自动化机器人系统进行检查也有显著的优点:多功能性、速度和可重复性,仅举几例。本文探讨了利用自动化机器人系统对复合材料零件进行无损检测。它侧重于相控阵超声检测(PAUT),但强调系统中的模块化原则,而不是与单一检测方法相耦合。由于多轴机器人固有的关节,如果系统模块设计正确,轮廓结构的检查变得简单。这些模块的例子,以及它们在与自动化机器人系统接口时的优势,都包括在本文中。这是作者的意图,以显示如何这些系统模块可能最大限度地提高机器人的能力,为广泛的航空航天检查,同时保持一个简单的设计,是模块化的,快速的,直接使用。与其他已经使用自动化机器人系统的航空航天制造过程相比,使用机器人进行无损检测似乎不仅是谨慎的,而且是一个有利的目标。本文为实现这一目标提供了实用的构建模块。
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引用次数: 0
Integrating Electromagnetic Acoustic Transducers in a Modular Robotic Gripper for Inspecting Tubular Components 将电磁声传感器集成到用于检测管状部件的模块化机器人夹具中
IF 0.6 4区 材料科学 Q4 MATERIALS SCIENCE, CHARACTERIZATION & TESTING Pub Date : 2021-07-01 DOI: 10.32548/2021.ME-04223
H. Nemati, Fernando Alvidrez, Ankit Das, Nihar Masurkar, Manoj Rudraboina, H. Marvi, E. Dehghan-Niri
Tubular structures are critical components in infrastructure such as power plants. Throughout their life, they are subjected to extreme conditions or suffer from defects such as corrosion and cracks. Although regular inspection of these components is necessary, such inspection is limited by safety-related risks and limited access for human inspection. Robots can provide a solution for automatic inspection. The main challenge, however, lies in integrating sensors for nondestructive evaluation with robotic platforms. As part of developing a versatile lizard-inspired tube inspector robot, in this study the authors propose to integrate electromagnetic acoustic transducers into a modular robotic gripper for use in automated ultrasonic inspection. In particular, spiral coils with cylindrical magnets are integrated into a novel friction-based gripper to excite Lamb waves in thin cylindrical structures. To evaluate the performance of the integrated sensors, the gripper was attached to a robotic arm manipulator and tested on pipes of different outer diameters. Two sets of tests were carried out on both defect-free pipes and pipes with simulated defects, including surface partial cracking and corrosion. The inspection results indicated that transmitted and received signals could be acquired with an acceptable signal-to-noise ratio in the time domain. Moreover, the simulated defects could be successfully detected using the integrated robotic sensing system.
管状结构是发电厂等基础设施的关键部件。在它们的整个生命周期中,它们都会受到极端条件的影响,或者会出现腐蚀和裂纹等缺陷。尽管有必要对这些部件进行定期检查,但此类检查受到安全相关风险和人员检查受限的限制。机器人可以为自动检测提供解决方案。然而,主要的挑战在于将用于无损评估的传感器与机器人平台集成。作为开发一种受蜥蜴启发的多功能管道检测机器人的一部分,在这项研究中,作者建议将电磁声换能器集成到一个模块化机器人夹具中,用于自动超声波检测。特别是,将带有圆柱形磁体的螺旋线圈集成到一种新型的基于摩擦的夹具中,以在薄圆柱形结构中激发兰姆波。为了评估集成传感器的性能,将夹具连接到机械臂上,并在不同外径的管道上进行测试。对无缺陷管道和具有模拟缺陷(包括表面局部开裂和腐蚀)的管道进行了两组测试。检测结果表明,在时域上可以以可接受的信噪比获取发射和接收信号。此外,使用集成机器人传感系统可以成功地检测模拟的缺陷。
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引用次数: 2
Aerial Robots for Contact-Based Ultrasonic Thickness Measurements for Field Inspections 用于现场检测的接触式超声厚度测量的航空机器人
IF 0.6 4区 材料科学 Q4 MATERIALS SCIENCE, CHARACTERIZATION & TESTING Pub Date : 2021-07-01 DOI: 10.32548/2021.ME-04213
Robert L. Dahlstrom
Aerial robotic systems, also referred to as drones, enable the collection of data on a scale and scope heretofore unimaginable. Field inspections at industrial sites using an aerial robotic inspection system that makes physical contact with a structure or asset as part of a nondestructive testing (NDT) or nondestructive evaluation (NDE) routine is safer than placing humans at elevation and enables more data to be gathered in less time. These aerial robotic systems are highly extensible and agile enabling safer, faster, and better inspections. Robotic inspection systems are forecast to grow exponentially this decade and beyond, as asset owners and service providers realize their economic value creation, increased data collection, and safety contributions.
空中机器人系统,也被称为无人机,能够以迄今无法想象的规模和范围收集数据。作为无损检测(NDT)或无损评估(NDE)常规的一部分,在工业现场使用空中机器人检测系统与结构或资产进行物理接触,这比将人员放在高处更安全,并且可以在更短的时间内收集更多数据。这些空中机器人系统具有高度可扩展性和灵活性,可以实现更安全、更快和更好的检查。随着资产所有者和服务提供商意识到他们创造的经济价值、增加的数据收集和安全贡献,机器人检测系统预计将在未来十年及以后呈指数级增长。
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引用次数: 0
Computed Tomography for the Nondestructive Testing of Additive Manufactured Components: Opportunities and Limitations 增材制造部件无损检测的计算机断层扫描:机遇与局限
IF 0.6 4区 材料科学 Q4 MATERIALS SCIENCE, CHARACTERIZATION & TESTING Pub Date : 2021-06-01 DOI: 10.32548/2021.ME-04207
Lennart Schulenburg
The additive manufacturing (AM) process has grown from university research laboratories into a production process for complex-shaped components. Due to the uniqueness of the manufacturing process, new challenges have arisen regarding process control, quality assurance, and surface finishing. This paper will show how the nondestructive radiographic testing (RT) technique computed tomography (CT) can make a valuable contribution to quality assurance at each step of the AM process. The use of CT is demonstrated using an example of chrome-nickel steel nozzles manufactured using the laser powder bed fusion (LPBF) process. The surface of the nozzles is then reworked with the Hirtisation process, a trademarked part finishing technology that is based on a combination of electrochemical pulse methods, hydrodynamic flow and particle assisted chemical removal, and surface treatment. In addition to the already known use of CT for detecting internal discontinuities, CT can be used to ensure sufficient wall thickness, measure internal channel surface roughness, and gauge the geometrical correctness of parts. In this paper, it is demonstrated how to use this RT technique to optimize the design and production process during the component development phase.
增材制造(AM)工艺已从大学研究实验室发展成为复杂形状部件的生产工艺。由于制造工艺的独特性,在工艺控制、质量保证和表面精加工方面出现了新的挑战。本文将展示无损射线检测(RT)技术计算机断层扫描(CT)如何在AM过程的每个步骤为质量保证做出有价值的贡献。CT的使用是通过使用激光粉末床熔化(LPBF)工艺制造的铬镍钢喷嘴的例子来证明的。然后使用Hirtisation工艺对喷嘴表面进行返工,Hirtisating工艺是一种基于电化学脉冲方法、流体动力学流动和颗粒辅助化学去除以及表面处理的商标零件精加工技术。除了已知的CT用于检测内部不连续性之外,CT还可用于确保足够的壁厚,测量内部通道表面粗糙度,并测量零件的几何正确性。在本文中,演示了如何在组件开发阶段使用这种RT技术来优化设计和生产过程。
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引用次数: 0
Design and Characteristics of Microfocus X-ray Source with Sealed Tube and Transmissive Target on Diamond Window 金刚石窗口透射靶密封管微聚焦X射线源的设计与特性
IF 0.6 4区 材料科学 Q4 MATERIALS SCIENCE, CHARACTERIZATION & TESTING Pub Date : 2021-06-01 DOI: 10.32548/2021.ME-04196
T. Tsunoda, Takeo Tsukamoto, Y. Ando, Yasuhiro Hamamoto, Yoichi Ikarashi, Satoshi Nagasato, K. Ueda
Electronic devices such as medical instruments implanted in the human body and electronic control units installed in automobiles have a large impact on human life. The electronic circuits in these devices require highly reliable operation. Radiographic testing has recently been in strong demand as a nondestructive way to help ensure high reliability. Companies that use high-density micrometer-scale circuits or lithium-ion batteries require high speed and high magnification inspection of all parts. The authors have developed a new X-ray source supporting these requirements. The X-ray source has a sealed tube with a transmissive target on a diamond window that offers advantages over X-ray sources having a sealed tube with a reflective target. The X-ray source provides high-power-density X-ray with no anode degradation and a longer shelf life. In this paper, the authors will summarize X-ray source classification relevant to electronic device inspection and will detail X-ray source performance requirements and challenges. The paper will also elaborate on technologies employed in the X-ray source including tube design implementations for high-power-density X-ray, high resolution, and high magnification simultaneously; reduced system downtime for automated X-ray inspection; and reduced dosages utilizing quick X-ray on-and-off emission control for protection of sensitive electronic devices.
植入人体的医疗器械、安装在汽车上的电子控制单元等电子设备对人类的生活产生了很大的影响。这些设备中的电子电路需要高度可靠的运行。射线检测作为一种有助于确保高可靠性的非破坏性方法,最近受到了强烈的需求。使用高密度微米级电路或锂离子电池的公司要求对所有部件进行高速和高倍检查。作者开发了一种新的支持这些要求的x射线源。该x射线源具有在菱形窗口上具有透射目标的密封管,其优于具有具有反射目标的密封管的x射线源。x射线源提供高功率密度的x射线,没有阳极降解和更长的保质期。本文将总结与电子设备检测相关的x射线源分类,并详细介绍x射线源的性能要求和挑战。本文还将详细介绍x射线源中采用的技术,包括高功率密度x射线,高分辨率和高放大倍率的管设计实现;减少了自动x射线检测的系统停机时间;并利用快速x射线开关发射控制来减少剂量,以保护敏感的电子设备。
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引用次数: 0
Resonance Bond Testing: Theory and Application 共振键合测试:理论与应用
IF 0.6 4区 材料科学 Q4 MATERIALS SCIENCE, CHARACTERIZATION & TESTING Pub Date : 2021-06-01 DOI: 10.32548/2021.ME-04225
Stetson Watkins, J. Bittner
Resonance bond testing is a nondestructive testing (NDT) technique that is used to detect disbonds, delaminations, and other voids in composite materials. The aerospace industry has seen an increase in the use of carbon fiber reinforced plastics (CFRP) for aircraft and spacecraft construction. Composite materials offer many advantages over traditional metallic structures, which include weight savings, increased strength, design for specific load paths, and the ability to easily construct geometrically complex structures. Resonance bond testing has many established uses for metallic structures as well, such as aluminum skin-to-skin and skin-to-core bonds. This bond testing technique has been around for many decades but is used by only a small portion of the NDT community. Ultrasonic testing (UT), specifically phased array ultrasonic testing (PAUT), using linear array techniques has proven to be a reliable method for the inspection of CFRP laminates. When composite structures do not permit the use of high-frequency sound waves due to rapid attenuation, resonance bond testing is a proven alternative. In this paper, the authors will discuss the theory behind resonance bond testing and how it has and continues to play an important role in the NDT industry.
共振键合检测是一种无损检测(NDT)技术,用于检测复合材料中的脱键、分层和其他空隙。航空航天工业在飞机和航天器建造中使用的碳纤维增强塑料(CFRP)有所增加。与传统金属结构相比,复合材料具有许多优点,包括减轻重量、增加强度、针对特定负载路径的设计以及轻松构建几何复杂结构的能力。共振键测试在金属结构中也有许多既定的用途,比如铝的皮对皮和皮对核键。这种粘结测试技术已经存在了几十年,但只有一小部分无损检测社区使用。超声检测(UT),特别是相控阵超声检测(PAUT),采用线性阵列技术已被证明是一种可靠的CFRP层合板检测方法。当复合材料结构由于快速衰减而不允许使用高频声波时,共振键合测试是一种经过验证的替代方法。在本文中,作者将讨论共振键合测试背后的理论,以及它如何在无损检测行业中发挥重要作用。
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引用次数: 0
A Deep Learning Framework for Acoustic Emission Sources Localization and Characterization in Complex Aerospace Panels 复杂航空航天面板声发射源定位和表征的深度学习框架
IF 0.6 4区 材料科学 Q4 MATERIALS SCIENCE, CHARACTERIZATION & TESTING Pub Date : 2021-04-01 DOI: 10.32548/2021.ME-04179
A. Ebrahimkhanlou, M. Schneider, B. Dubuc, S. Salamone
This paper presents a data-driven approach based on deep stacked autoencoders for the localization and characterization of acoustic emission sources in complex aerospace panels. The approach leverages the multimodal and dispersive reverberations of acoustic emissions. The approach is validated by Hsu-Nielsen pencil lead break tests on a fuselage section of a Boeing 777 instrumented with a single piezoelectric sensor.
本文提出了一种基于深度堆叠自编码器的数据驱动方法,用于复杂航天板声发射源的定位和表征。该方法利用了声发射的多模态和弥散混响。Hsu-Nielsen在波音777机身部分进行了铅笔芯断裂测试,该测试采用了单个压电传感器。
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引用次数: 4
Monitoring of Elastoplastic Fracture Behavior of HSLA Steel Using Acoustic Emission Testing 声发射法监测HSLA钢弹塑性断裂行为
IF 0.6 4区 材料科学 Q4 MATERIALS SCIENCE, CHARACTERIZATION & TESTING Pub Date : 2021-04-01 DOI: 10.32548/2021.ME-04137
J. Kumar, C. Mukhopadhyay, V. Kumar
The present study explores using acoustic emission testing (AE) to monitor the elastoplastic fracture toughness (JIC) of high-strength, low-alloy (HSLA) steel in two different orientations. Acoustic emission signals generated during the tests were found to be higher during bulk yielding upon initial loading, after which they decreased during intermediate loading before increasing again. The acoustic emission signals generated were used to correlate with the JIC values determined from unloading compliance tests. The point of crack initiation estimated by AE is lower than that determined by the unloading compliance tests. Beyond the point of crack initiation determined by AE, the acoustic emission signals generated increased rapidly, which is attributed to crack growth. The results of AE during crack initiation are supported by the peak amplitude of the acoustic emission signals. The possibility of using AE data to estimate fracture toughness values has also been explored for HSLA steel.
本研究探索使用声发射测试(AE)来监测高强度低合金(HSLA)钢在两个不同方向上的弹塑性断裂韧性(JIC)。试验过程中产生的声发射信号在初始加载时的整体屈服过程中较高,之后在中间加载过程中降低,然后再次增加。产生的声发射信号用于与卸载顺应性试验确定的JIC值相关。AE估算的裂纹萌生点低于卸载顺应性试验确定的裂纹萌生。在AE确定的裂纹萌生点之外,产生的声发射信号迅速增加,这归因于裂纹的扩展。声发射信号的峰值振幅支持了裂纹萌生过程中的声发射结果。还探讨了利用声发射数据估算HSLA钢断裂韧性值的可能性。
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引用次数: 1
Eddy Current Testing Basics and Innovation 涡流检测的基础与创新
IF 0.6 4区 材料科学 Q4 MATERIALS SCIENCE, CHARACTERIZATION & TESTING Pub Date : 2021-04-01 DOI: 10.32548/2021.ME-04218
C. Wassink, M. Grenier, Mitchell Sirois, Anna M. Allard, Jonathan Berthier
Eddy current testing is considered a theoretically challenging technique. Out of all the different nondestructive testing (NDT) methods, the electromagnetic testing (ET) method (of which eddy current testing is a technique) is probably the most difficult for understanding theory. This is perhaps why the last Materials Evaluation Back to Basics paper on eddy current testing is from 2006, which is a long time ago given the amount of innovation in the technique that has taken place since then (Hansen and Peoples 2006). In this paper we will show what has changed due to recent innovations. We first will present the physics, and then explain how modern equipment assists the user in distinguishing between different physical phenomena. Although this paper is on conventional eddy current testing, we will also mention some other ET techniques along with their advantages and disadvantages.
涡流测试被认为是一种理论上具有挑战性的技术。在所有不同的无损检测方法中,电磁检测(ET)方法(其中涡流检测是一种技术)可能是最难以理解的理论。这也许就是为什么最后一篇关于涡流测试的材料评估回归基础的论文是在2006年发表的,考虑到自那以后技术上的大量创新,这是很久以前的事情了(Hansen and Peoples 2006)。在本文中,我们将展示由于最近的创新而发生的变化。我们将首先介绍物理,然后解释现代设备如何帮助用户区分不同的物理现象。虽然本文是关于传统的涡流测试,但我们也会提到一些其他的ET技术及其优缺点。
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引用次数: 1
Role of Women in the Pursuit of NDE 4.0 女性在追求濒死体验4.0中的角色
IF 0.6 4区 材料科学 Q4 MATERIALS SCIENCE, CHARACTERIZATION & TESTING Pub Date : 2021-03-01 DOI: 10.32548/2021.ME-04215
Ripi Singh, M. Miceli
This paper is intended to highlight roles that women can and likely will play in shaping the future of NDE 4.0, from execution to leadership levels as well as from development to transformation activities. As we build momentum toward adopting Industry 4.0 into the nondestructive evaluation (NDE) domain, we face multiple challenges such as technology standardization, talent and skills shortfall, massive transformation, and regulatory and certification standards (Singh 2019, 2020a). Many of these challenges are better addressed with a proper mix of gender in responsible teams. Women in STEM (science, technology, engineering, and mathematics) fields are a source of talent that can be harnessed as digitalization becomes a major part of the NDE sector. According to a recent Forbes article, traits like listening and empathy serve women well in “change leadership,” which is the ability to influence and inspire action in others and respond with vision and agility during periods of growth, disruption, or uncertainty to bring about the needed change (Lipkin 2019). While working the innovation value chain, emotional intelligence makes women better suited to capturing marketplace insight and easing friction in technology adoption, and a balance of gender in a team makes for more productive ideation sessions for effective problem-solving and objective execution. This paper presents literature research triggered by personal experience and substantiated by recent candid conversations with women leaders in NDE, to highlight the importance of a blended and balanced gender mix required for NDE 4.0.
本文旨在强调女性在塑造NDE 4.0的未来方面可以而且可能发挥的作用,从执行到领导层,以及从发展到转型活动。随着我们在无损评估领域采用工业4.0的势头越来越大,我们面临着技术标准化、人才和技能短缺、大规模转型以及监管和认证标准等多重挑战(Singh 20192020a)。在负责任的团队中适当混合性别,可以更好地应对其中的许多挑战。STEM(科学、技术、工程和数学)领域的女性是可以利用的人才来源,因为数字化成为无损检测部门的主要组成部分。根据《福布斯》最近的一篇文章,倾听和同理心等特质在“变革领导力”中很好地服务于女性,“变革领导力是指在成长、中断或不确定时期影响和激励他人行动的能力,并以远见和敏捷性做出回应,以实现所需的变革(Lipkin 2019)。在创新价值链中工作时,情商使女性更适合捕捉市场洞察力,缓解技术采用中的摩擦,团队中的性别平衡有助于更有效地解决问题和客观执行。本文介绍了由个人经历引发的文献研究,并通过最近与NDE中的女性领导者的坦诚对话得到证实,以强调NDE 4.0所需的混合和平衡的性别组合的重要性。
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引用次数: 2
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