Continuous monitoring of an intentionally-manufactured crack using an automated welding and in-process inspection system. (June 2020)

• Record Type: Journal Article
• Authors: Javadi, Yashar; Mohseni, Ehsan; MacLeod, Charles N.; Lines, David; Vasilev, Momchil; Mineo, Carmelo; Foster, Euan; Pierce, Stephen G.; Gachagan, Anthony
• Is Part Of: Materials & design. Volume 191(2020)
• Publication Date: 2020-06
• Subjects: Crack growth monitoring -- Ultrasonic phased array -- In-process inspection -- Robotic NDE -- Intentionally manufactured weld defects -- Robotic welding; Materials -- Periodicals; Engineering design -- Periodicals; Matériaux -- Périodiques; Conception technique -- Périodiques; Electronic journals; 620.11
• DOI: 10.1016/j.matdes.2020.108655
• Languages: English
• ISSNs: 0264-1275

Abstract

Abstract: Automated weld deposition coupled with the real-time robotic Non-Destructive Evaluation (NDE) is used in this paper. For performance verification of the in-process inspection system, an intentionally embedded defect, a tungsten rod, is introduced into the multi-pass weld. A partially-filled groove (staircase) sample is also manufactured and ultrasonically tested to calibrate the real-time inspection implemented on all seven layers of the weld which are deposited progressively. The tungsten rod is successfully detected in the real-time NDE of the deposited position. The same robotic inspection system was then used to continuously monitor an intentionally-manufactured crack for 20 h. The crack was initiated 22 min after the weld ended and it grew quickly within the next 1.5 h. The crack growth stopped approximately after 2 h and no considerable change in the reflection signal was detected for the next 18 h of monitoring. Graphical abstract: Unlabelled Image Highlights: Automated weld deposition coupled with the real-time robotic NDT is discussed. An intentionally embedded defect, a tungsten rod, is introduced for verification. A partially-filled groove sample is also manufactured and ultrasonically tested. The system is then used for continuous monitoring of a crack for 20 h. The crack was initiated 22 min after the weld and grew for 1.5 h.