Advanced NDE Technologies for Quality Control November 9 th, 2012 Dr. Jeong Na Technology Leader NDE Group 1250 Arthur E. Adams Drive Columbus, OH 43221

Advacned NDE Technologies  Matrix Phased Array (MPA) Ultrasonics  Laser Based Ultrasonics  Array Eddy Current  Ultrasonically Induced Thermography

Linear Phased Array UT  One-Dimensional Array Configuration  Line Focusing, Steering and Electronic Scanning FocusingSteeringScanning Piezo Elements

Matrix Phased Array (MPA) Technology  Provides 2-Dimensional Electronic Control of Beam: Focusing, Steering, and Scanning Each bar represents firing delay for each element

3-D MPA Probe  Convex Surface Contour  No Requirement of Steering  Less Number of Elements (8x8)  Lower Frequency (12 MHz)

Automotive Resistance Spot Welds  Provides 2-D Image of Weld Nugget along with Diameter and Area Information 6 mm RSW Screen Shot

Probability of Detection (POD)  Nugget Size Ranged between mm for Two 0.7 mm Sheets  One Hundred Weld Samples  Approximately 98% Accuracy in Sizing Weld Nugget Diameter (0.7 mm Thickness) Avg. Peel/Chisel Destructive Test Dia. (mm) Avg. UT Dia. (mm) UT vs Destructive Ideal 95% LUS

Laser Based Ultrasonics Non-contact Fast Scan Complex Geometries Hostile Environments High Spatial Resolution Versatile – Very small to Very Large Parts 1.Laser Generation 2.Laser Detection 3.Hardware, electronics, computers

Elastic Waves V L > V S > V R Sound Velocity:

Weld Joint Inspection Levesque et.al. “Defect Detection and Residual Stress Measurement in Friction Stir Welds using Laser Ultrasonics”, LU Butt Joint Decreasing lack of penetration along weld  Weld Joint

Mechanical Properties Blouin et. al. “Detection of Skin Disbond in Honeycombs and Coating Detachment by Laser Tapping Technique”, LU Honeycomb delamination and disbond

Fundamentals of Eddy Current No FlawWith Flaw

Array Eddy Current Technology Spot ASpot B 32 Element Array Probe Scanner

Example - FSW Inspection FSW  Friction Stir Welded Aluminum Plate (1” thick)  32 Element Flexible Eddy Current Probe (Multi Frequency) Scan Direction

Inspection Results 20 kHz480 kHz

Ultrasonically Induced Thermography Fast and Non-Contact Inspection Easy to Interpret Inspection Results

Ultrasonic Induced Thermography Through Transmission Measurement Single Side Measurement Ultrasonic Horn Temperature Sensor

Example (Resistance Spot Welded Thin Metal Plates) Good WeldBad Weld X-ray image showing weld nuggets (2 mm diameter RSW)

Correlation to Pull Strength

Summary  Wide range of inspection applications with matrix phased array technology with accuracy and reliability  Laser based ultrasonics is getting widely used across the board as a fast non-contact inspection tool  Imaging capability of array eddy current can reduce operator dependency with easy to understand inspection results  Non-contact ultrasonically induced thermography technique makes it possible to develop a high speed automated inspection system for weld quality as well as bond quality