ENT604 Testing And Inspection In Manufacturing PDF

TESTING AND INSPECTION IN MANUFACTURING Professor Rossi Setchi [email protected], S/2.41 Outline After studying this topic, you will be able to: understand the symbiosis of testing and inspection, and their significance in manufacturing. acquire basic understanding of NDT/NDE under...

TESTING AND INSPECTION IN MANUFACTURING Professor Rossi Setchi [email protected], S/2.41 Outline After studying this topic, you will be able to: understand the symbiosis of testing and inspection, and their significance in manufacturing. acquire basic understanding of NDT/NDE understand the main measurement techniques used elucidate typical NDT/NDE applications  The Symbiosis of Testing and Inspection Testing involves subjecting products to various conditions to evaluate their performance, functionality and durability. Testing aims to replicate real-world usage, identify weaknesses and potential failure points. Scanning of composite A350 wing skin during GE Aviation wind tunnel during production maintenance  The Symbiosis of Testing and Inspection Inspection is about scrutinizing each component to ensure it adheres to specified specifications, and overall compliance with standards. Inspection uncovers defects, irregularities or deviations from standards. Early detection allows for corrective measures. Automated ultrasound rail wheel inspection and portable rail flaw detector  Case Study: Building the A350 Wings in Wales Airbus plant in Broughton, North Wales has four separate wing production buildings. The A350 line is as big as Wembley Stadium. 550 people work there, and it takes 5 days to assemble an A350 wing. The A350 wing has been developed using over 4000 hours of wind tunnel time. From Spain to Wales to Germany, to reach finally Toulouse for the final assembly The lower skin of the A350 wing just after arrival in Broughton. The Bremen team installs all the ‘high lift’ systems and hydraulics.  Case Study: Testing New Cars (1) This £100m facility in Warwickshire is used for physical and virtual testing of human-driven and autonomous, electric and combustion, civilian and military vehicles. It is used for testing a range of scenarios involving advanced driver assistance systems and connected and autonomous vehicles, such as lane merging, lane assist, platooning, and autonomous emergency braking. The ‘highway’ testing facility has a fully Testing durability and level of configurable dynamic platform with an approach autonomy. © HORIBA MIRA 15 lanes wide. Recreating real road conditions, junctions, roundabouts, on-street parking bays … The deliberately worn-down or varying line markings on road surfaces are designed to create a safe, controlled environment that will challenge driver Case Study: Testing New Cars (2) In-door car self-parking without signals from global navigation satellite systems (GNSS) cannot penetrate steel structures. Digital twins, simulators and VR caves have reduced the amount of physical testing required. A key benefit of using simulators and test rigs instead of test vehicles and prototypes is decarbonisation. Replacing a physical prototype with a virtual one slashes emissions, tyre usage and component consumption. An engineer tests a vehicle in the driving simulator © HORIBA MIRA Case Study: Field Testing in Japan (1) Honda’s MC-β, a micro-sized EV for short distances and commuting Case Study: Field Testing in Japan (2) Agricultural robotics  Case Study: Crashing Cars to Improve Safety (1) Impact testing is used to ensure safe design standards for modes of transportation including cars, aircraft and wheelchairs. Gathering data from high-speed cameras, triaxial accelerometers, and sensors embedded in crash test dummies to measure the potential damage in different impact scenarios. An engineer inspects the damage and takes post-crash measurements © Thatcham Research How are crash test dummies being developed to be more representative of the general population?  Case Study: Crashing Cars to Improve Safety (2) Crash test dummies are fitted with hundreds of transducers. A reference point on the dummy called the h-point (where the standard hip is) has a positioning tolerance of +- 13 mm. This level of accuracy allows the Crash test dummies must be positioned very tests to be directly compared across accurately © Thatcham Research different vehicles; any variation in dummy positioning would introduce too many variables. It takes 4 days to prepare a test, which takes just 200 msec, and may cost £100k. Destructive vs Non- Destructive Testing NDT/NDE use noninvasive techniques in testing and inspection to determine the integrity of a material, component or structure (NDT) and assess and quantitatively measure 3D scanner for surface inspection some characteristics of an object (NDE). Product integrity and surface texture remain unchanged. While NDT is restricted to testing, NDE includes both testing and the evaluation of the results. That is, NDT is used to locate defects in an asset while NDE is used to locate defects while also measuring the size, shape, orientation, and other physical characteristics of the defect. NDE often uses data analytics.  Common Application of NDT Inspection of raw products (forgings, castings, extrusions, etc.) Inspection following processing (machining, welding, grinding, heat treatment, plating, etc.) In-services damage inspection cracking, corrosion, erosion, wear, heat damage, etc. – dimensions, microstructure, chemical composition flaw detection, leaks, location Industrial Sectors, which Use NDE Energy Oil and gas What is the connection between all these sectors? Construction Aerospace Case Study: NDT in the Oil and Gas Industry What is the business case for using NDT? Watch the full video at https://www.youtube.com/watch?v=lrb2-Icx7vc Typical NDT Methods  Comparison Consideration Liquid penetrant Magnetic Radiography Eddy current Ultrasound particles/electromagnetic testing Industry/applications Effect Capillary action caused Magnetisation. Any Electromagnetic radiation Electro-magnetic induction Propagation by the intermolecular discontinuity in the material (X-rays or Gamma-rays) of ultrasonic waves in the forces between the liquid allows the magnetic flux to with short wavelength material tested and the solid surfaces leak. Materials Normally metals but also concrete, wood and composites Cost Low to medium (low/medium/high) Availability of result Short delay Short delay Delayed Short delay Immediate (immediately/short delay/delayed) Geometry Important (solid, flat Not important Important (important/non material or hollow important) cylindrical or spherical object) Type of defect Surface defects Surface and near surface External & internal Surface and subsurface Internal (internal/external/surf defects defects ace/near surface) Operator skill Low (low/medium/high) Ability to automate Good Fair Good (poor/fair/good)  Visual Inspection (1) P/11 is National Grid’s procedure for inspecting, assessing and repairing damaged high-pressure steel pipelines. Data acquisition by 3D scanner at National Grid: faster, more accurate. Previously an hour was spent setting up the instrumentation (e.g. depth micrometre) before any measurements can be taken. https://www.youtube.com/watch?v=W1AbNDrBKTM  Visual Inspection (2) Pipeline inspection workflow using drones and a thermal imaging camera. Thermography is the process of creating an image of an object by using infrared radiation emitted from the object. Thermal imaging cameras equipped to aerial and underwater drones are used to identify heat loss in buildings, roof leaks, leaking pipes, water ingress, missing insulation, creaks in structures, damp and structural weak points. What are the benefits of using https://www.youtube.com/watch?v=HO6H67Ew-K0 drones? Are there limitations?  Visual Inspection (3) The robot inspects the predefined locations for the finest of cracks using a thermographic sensor unit. The procedure involves first stimulating the area to be inspected with an electronic impulse, and then photographing it with an infra-red camera. This produces a temperature profile which allows for even the smallest cracks to be identified. Data acquisition by drones only takes 10 to 15 minutes, instead of 2 hours using conventional methods. https://www.youtube.com/watch?v=dUrnYyqsEt0  Liquid Penetrant Inspection https://www.youtube.com/watch?v=NFbsvWo2SzA A liquid with high surface wetting characteristics is applied to the surface of the part and allowed time to seep into surface breaking defects. https://www.youtube.com/watch?v=mIXIcR59dRE The excess liquid is removed from the surface of the part. A developer (powder) is applied to pull the trapped penetrant out the defect and spread it on the surface where it can be seen. The penetrant is often loaded with a fluorescent dye and the inspection is done under UV light to increase test sensitivity.  Magnetic Particle Inspection When the part is magnetised with a magnetic field, a discontinuity (defect) on the surface causes the ferromagnetic particles to gather visibly around the defect. The iron particles may be coated with a dye pigment for better visibility on metal surfaces. The defect then becomes a magnet, due to flux leakages where the magnetic field lines are interrupted by the defect. This creates a small- scale N-S pole at either side of the defect as field lines exit the surfaces. The particles take the shape and size of the defect. Subsurface defects can be detected too. http://www.youtube.com/watch?v=qpgcD5k1494  Radiography Radiography involves x-ray inspection to detect such internal flaws as cracks and porosity. On an x-ray image, the metal surrounding a defect is typically denser, and thus shows up as lighter than the flaws. https://www.youtube.com/watch?v=-ms1j72S4uk  Eddy Current Testing Eddy current testing is particularly well suited for detecting surface cracks but can also be used to make electrical conductivity and coating thickness measurements. The method is based on the principle of electromagnetic induction. https://www.youtube.com/watch?v=NIYUgvJFasc Coil's Coil magnetic field Eddy current's magnetic field Eddy currents Conductive material  Ultrasonic Inspection (Pulse-Echo) High frequency sound waves are introduced into a material, and they are reflected from surfaces (e.g. back wall of the object) or imperfections. Reflected sound energy is displayed versus time. The diagnostic machine displays these results in the form of a signal with an amplitude representing the intensity of the reflection and the distance, representing f the arrival time of the reflection. https://www.youtube.com/watch?v=UM6XKvXWVFA  Case Study: Ultrasonic Armour Inspection The British military ships around 5 million armour units per year from around the world back to the UK to be inspected by X-rays. Cardiff innovation: a handheld device that can conduct ultrasonic inspections and process the f results to give a simple pass or fail answer. A-Ultra scans a helmet for damage © Microchip The system works by creating energy – similar to a miniature earthquake – releasing it through the structure. Four miniature sensors are are applied to the body armour. The sensors are lightweight and unobtrusive within the armour. They are mounted on flexible circuits that can be easily installed and fitted to various shapes depending on the application. If one sensor fails, the remaining three will still be able to give a reading. https://www.ingenia.org.uk/articles/ultrasonic-armour-inspection/  Comparison Consideration Liquid penetrant Magnetic Radiography Eddy current Ultrasound particles/electromagnetic testing Industry/applicatio Aerospace Pipelines, Wire ropes Pipelines, Pressure Aerospace, Power Rail, Aerospace, ns vessels plants, Petrochemical Bridges, Storage tanks, Pressure vessels Effect Capillary action Magnetisation. Any Electromagnetic radiation Electro-magnetic Propagation caused by the discontinuity in the material (X-rays or Gamma-rays) induction of ultrasonic waves in intermolecular allows the magnetic flux to with short wavelength the material tested forces between the leak. liquid and the solid surfaces Materials All materials Ferromagnetic materials A large variety of materials Conductive (e.g. Normally metals but (e.g. iron, nickel, cobalt) (metal, concrete, ceramics, copper, aluminium, also concrete, wood etc.) gold, silver) and composites Cost Low to medium Medium High Medium Medium to high (low/medium/high) Availability of Short delay Short delay Delayed Short delay Immediate result (immediately/short delay/delayed) Geometry Not important Not important Important (solid, flat Not important Important (important/non material or hollow important) cylindrical or spherical object) Type of defect Surface defects Surface and near surface External & internal Surface and subsurface Internal (internal/external/s defects defects urface/near surface)  Aircraft Inspection Nondestructive testing is used extensively during the manufacturing of aircraft. NDT is also used to find cracks and corrosion damage during operation of the aircraft. A fatigue crack that started at the site of a lightning strike is shown below.  Jet Engine Inspection Aircraft engines are overhauled after being in service for a period of time. They are completely disassembled, cleaned, inspected and then reassembled. Fluorescent penetrant inspection is used to check many of the parts for cracking.  Rail Inspection Special cars are used to inspect thousands of miles of rail to find cracks that could lead to a derailment. Ultrasound inspection in rail industry  Wire Rope Inspection Electromagnetic devices and visual inspections are used to find broken wires and other damage to the wire rope that is used in chairlifts, cranes and other lifting devices.  Bridge Inspection Corrosion, cracking and other damage can all affect a bridge’s performance. Bridges get a visual inspection about every 2 years. Some bridges are fitted with acoustic emission sensors that “listen” for sounds of cracks growing.  Pipeline Inspection NDT is used to inspect pipelines to prevent leaks that could damage the environment. Visual inspection, radiography and electromagnetic testing are some of the NDT methods used.  Power Plant Inspection Periodically, power plants are shutdown for inspection. Inspectors feed eddy current probes into heat exchanger tubes to check for corrosion damage. Eddy current in petrochemical and power generation Pipe with damage Probe Signals produced by various amounts of corrosion thinning.  Storage Tank Inspection Robotic crawlers use ultrasound to inspect the walls of large above ground tanks for signs of thinning due to corrosion. Cameras on long articulating arms are used to inspect underground storage tanks for damage.  Pressure Vessel Inspection The failure of a pressure vessel can result in the rapid release of a large amount of energy. To protect against this dangerous event, the tanks are inspected using radiography and ultrasonic testing.  Future Opportunities AI Robotics and automation Internet of Things