1. 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

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

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

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

5. 3-D MPA Probe  Convex Surface Contour  No Requirement of Steering  Less Number of Elements (8x8)  Lower Frequency (12 MHz)

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

7. Probability of Detection (POD)  Nugget Size Ranged between 4 - 6 mm for Two 0.7 mm Sheets  One Hundred Weld Samples  Approximately 98% Accuracy in Sizing Weld Nugget Diameter (0.7 mm Thickness) 0.0 2.0 4.0 6.0 8.0 10.0 0.02.04.06.08.010.0 Avg. Peel/Chisel Destructive Test Dia. (mm) Avg. UT Dia. (mm) UT vs Destructive Ideal 95% LUS

8. 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

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

10. Weld Joint Inspection Levesque et.al. “Defect Detection and Residual Stress Measurement in Friction Stir Welds using Laser Ultrasonics”, LU 2008. Butt Joint Decreasing lack of penetration along weld  Weld Joint

11. Mechanical Properties Blouin et. al. “Detection of Skin Disbond in Honeycombs and Coating Detachment by Laser Tapping Technique”, LU 2008. Honeycomb delamination and disbond

12. Fundamentals of Eddy Current No FlawWith Flaw

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

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

15. Inspection Results 20 kHz480 kHz

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

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

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

19. Correlation to Pull Strength

20. 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