TY - CONF A1 - Hassenstein, Christian T1 - Automated self-adjustment of array probe with a robotic ultrasonic test system N2 - Ultrasonic testing (UT) of objects with complex geometries often requires the use of a robotic arm to position the probe perpendicular to the local surface. Using immersion makes it possible to test these objects with standard ultrasonic linear array probes. Here, the probe positions and orientations provided by the robot are used for merging the locally acquired image data into a 3D-reconstruction. The quality of this reconstruction is highly dependent on the alignment of the tool center point (TCP) of the physical probe with the TCP used in the digital model. For common industrial tools, the TCP is usually acquired using geometric features of the tools. However, for ultrasonic arrays in immersion, there is a water standoff between the probe and the test object, therefore the TCP is in free space in front of the array and cannot be acquired with the common method. To overcome this challenge, we propose a method that allows the robotic ultrasonic system to automatically self-adjust the positioning of the UT probe using a test block made of steel with defined geometric features as a target for referencing. For each of the six degrees of freedom, a scan and adjustment routine are established using the data acquired by the UT probe to update the TCP’s position and orientation in the robot control. Given a coarse pre-definition of the TCP and the known target test block, no human interaction is required while the system determines the optimum tool position and orientation. Part of this work will be used to improve and extend standards for robotic ultrasonic test systems, e.g. ISO 24647. T2 - 20th World Conference On Non-Destructive Testing CY - Incheon, South Korea DA - 27.05.2024 KW - Ultrasonic KW - Testing KW - Automation KW - Robotics KW - NDT 4.0 PY - 2024 AN - OPUS4-60565 LA - eng AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - CONF A1 - Hassenstein, Christian T1 - Automatisierte Wanddickenbestimmung an Prüfteilen mit komplexen Geometrien aus anisotropen Werkstoffen N2 - Im Rahmen des Projektes MRO2.0, das sich mit der digitalen Transformation des Servicezyklus von modernen Gasturbinenschaufeln beschäftigt, wurde gezeigt, wie sich automatisiert und flächendeckend die (Rest-)Wanddicke an variabel gekrümmten Prüfgeometrien bestimmen lässt. Es wurde ein Roboterarm verwendet, der ein lineares Ultraschallarray in Tauchtechnik führt und Prüfdaten aufnimmt, die mit einer adaptierten TFM (Total Focusing Method) zu Rekonstruktionen der Außen- und Innenoberfläche verarbeitet werden. In der aktuellen zweiten Projektphase wird die Methode für Werkstoffe erweitert, die anisotrope akustische Eigenschaften aufweisen. In diesem Beitrag wird eine Methode vorgestellt, wie sich die Kristallausrichtung bzw. die richtungsabhängige Schallgeschwindigkeit mittels eines linearen Ultraschallarrays bestimmen lässt. Für den Sendefall eines Randelements in Kontakttechnik können dabei Wellen identifiziert werden, die sich parallel zur Prüfkopfapertur im Prüfobjekt ausbreiten und mit der richtungsabhängigen Schallgeschwindigkeit skalieren. Die ermittelte Schallgeschwindigkeitsverteilung kann dann verwendet werden, um die lokale Wanddickenbestimmung für die Anisotropie zu adaptieren. T2 - 6. Workshop Messtechnische Anwendungen von Ultraschall CY - Drübeck, Germany DA - 17.06.2024 KW - Ultraschallprüfung KW - Anisotropie KW - Turbinenschaufel KW - NDT 4.0 PY - 2024 AN - OPUS4-60568 LA - deu AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - CONF A1 - Hassenstein, Christian A1 - Hirsch, Philipp Daniel A1 - Wassermann, Jonas A1 - Heckel, Thomas T1 - Automated self-adjustment of array probe with a robotic ultrasonic test system N2 - Ultrasonic testing of objects with complex geometries often requires the use of a robotic arm to position the probe perpendicular to the local surface. Using immersion makes it possible to test these objects with standard ultrasonic linear array probes. Here, the probe positions and orientations provided by the robot are used for merging the locally acquired image data into a 3D-reconstruction. The quality of this reconstruction is highly dependent on the alignment of the position of the physical probe with the position used in the digital model. For common industrial tools, the tool center point (TCP) is usually acquired using geometric features of the tools. However, for ultrasonic arrays in immersion, there is a water standoff between the probe and the test object, therefore the TCP is in free space in front of the array and cannot be acquired with the common method. To overcome this challenge, we propose a method that allows the robotic ultrasonic system to automatically self-adjust the position and orientation of the ultrasonic probe using a test block made of steel with defined geometric features as a target for referencing. For each of the six degrees of freedom, a scan and adjustment routine are established using the data based on the actual ultrasound characteristics of the probe. Given a coarse pre-definition of the tool position and the known target test block, minimal human interaction is required to supervise the adjustment method, leading to higher quality reconstructions than with manual adjustment. T2 - 20th World Conference On Non-Destructive Testing (WCNDT 2024) CY - Incheon, South Korea DA - 27.05.2024 KW - Testing KW - Automation KW - NDT 4.0 KW - Robotics KW - Ultrasonic PY - 2024 UR - https://nbn-resolving.org/urn:nbn:de:kobv:b43-616387 UR - https://www.ndt.net/search/docs.php3?id=30309 SN - 1435-4934 SP - 1 EP - 9 PB - NDT.net AN - OPUS4-61638 LA - eng AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - CONF A1 - Hirsch, Philipp Daniel T1 - Robotic-assisted 3D scanning and laser thermography for crack inspection on complex components N2 - The integration of automation and robotics into inspection processes has marked a transformative shift in the evaluation of complex components. This study presents a novel approach employing robotic-assisted laser thermography for the automated identification and in-depth analysis of cracks in these intricate structures. This method not only streamlines the inspection process but also eliminates the need for numerous manual steps and the use of chemicals associated with traditional methods such as dye penetrant testing. With the increasing com-plexity of components, this is an important step, especially with regard to additively manufactured components, in order to be able to guarantee component safety for a long lifecycle. T2 - 17th Quantitative InfraRed Thermography Conference (QIRT) CY - Zagreb, Croatia DA - 01.07.2024 KW - Robot KW - Flying line KW - Crack detection KW - Robot path planning KW - Thermography PY - 2024 AN - OPUS4-60914 LA - eng AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - CONF A1 - Lecompagnon, Julien A1 - Ricci, M. A1 - Laureti, S. A1 - Ziegler, Mathias ED - Maldague, X. T1 - Practical study on the thermographic detectability of internal defects using temporally structured laser heating N2 - Modern laser systems have proven to be highly versatile heat sources for active thermographic testing. Compared to more traditional light sources, e.g. flash or halogen lamps, their output power can be easily modulated at high rates, allowing a wide variety of complex excitations to be realized. Although their total optical output power can be theoretically scaled to arbitrary values, the maximum output power is practically limited by many factors: the maximum power that the sample under test can absorb without altering the lighted surface itself, the trade-off between irradiance and inspected area, the cost of the laser system, etc. Furthermore, when working with spatial modulator systems, the output power must be limited to avoid damaging such devices. Nevertheless, to guarantee a sufficient amount of heating even for highly thermally conductive materials and/or deeply buried defects, the heating times can be extended, e.g., either by using step heating, long pulse thermography, or by lock-in thermography with a continuously modulated heating. However, for all these approaches, the ranging capabilities of the thermographic defect detection are reduced due to the limited frequency content of the excitation. To tackle this problem, i.e. to increase the excitation energy while preserving its frequency content, new approaches have been developed in the last two decades, among them the use of coded excitations in combination with pulse-compression, and the use of multiple lock-in analysis or a frequency modulated excitation signal. The challenges of such temporally structured heating techniques are manifold, for example, the DC component inherent in optical heating must be taken into account. In general, a wider frequency bandwidth or greater variability of the frequency components also means greater complexity for signal generation and data processing. In this paper, temporally structured excitation schemes with different degrees of complexity are compared on a high-power laser system. T2 - 17th International Conference on Quantitative InfraRed Thermography 2024 CY - Zagreb, Croatia DA - 01.07.2024 KW - Thermography KW - Laser KW - NDT KW - Coded excitation KW - Defect identification PY - 2024 UR - https://nbn-resolving.org/urn:nbn:de:kobv:b43-653790 DO - https://doi.org/10.21611/qirt-2024-077 SN - 2371-4085 SP - 1 EP - 9 PB - QIRT Council AN - OPUS4-65379 LA - eng AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - CONF A1 - Hirsch, Philipp Daniel A1 - Kunji Purayil, Sruthi Krishna A1 - Lecompagnon, Julien A1 - Pech May, Nelson Wilbur A1 - Ziegler, Mathias ED - Maldague, X. T1 - Robotic-Assisted 3D Scanning and Laser Thermography for Crack Inspection on Complex Components N2 - The integration of automation and robotics into non-destructive testing (NDT) marks a significant advancement in evaluating complex components. This paper introduces a novel approach using robotic-assisted laser thermography combined with automated 3D scanning to detect and analyze cracks in complex structures. The system uses an integrated line scanner with a robotic arm to capture high-resolution data, creating detailed 3D models for adaptive path planning and precise alignment correction. Laser thermography, based on localized heating and the "flying spot" approach, detects surfacenear cracks with high precision. Crack detection is achieved using the Canny algorithm optional on Fourier-transformed thermograms, offering robust results with minimal computation. This study highlights the potential of robotic-assisted 3D scanning and laser thermography as efficient and precise methods for crack inspection, advancing NDT technologies and ensuring the structural integrity of modern components. T2 - 17th International Conference on Quantitative InfraRed Thermography 2024 CY - Zagreb, Croatia DA - 01.07.2024 KW - Thermography KW - Non-destructive testing KW - Laser line KW - Robotic arm KW - Defect identification KW - Crack detection PY - 2024 UR - https://nbn-resolving.org/urn:nbn:de:kobv:b43-653809 DO - https://doi.org/10.21611/qirt-2024-078 SP - 1 EP - 8 PB - QIRT Council AN - OPUS4-65380 LA - eng AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - CONF A1 - Kunji Purayi, Sruthi Krishna A1 - Hirsch, Philipp Daniel A1 - Lecompagnon, Julien T1 - Anisotropy investigation of a single crystal superalloy using laser-spot infrared thermography N2 - Thermal property investigation of anisotropic materials such as single crystal superalloys are still in interest of practical and fundamental reasons but remains challenging using conventional testing methods. In this study, a single crystal superalloy is tested using laser-spot thermography, and its thermal anisotropy is investigated. Determining anisotropic thermal conductivity at microscopic scales is challenging, as it appears isotropic at the macroscopic scale. Infrared thermography is one of the best-known techniques for measuring material heat transfer properties and facilitating visualization of temperature distribution through the specimen. The proposed study uses the active thermography method of laser-spot infrared thermography, in which a laser spot is focused onto the sample surface and the thermal response is captured from the surface of the specimen with an infrared camera. A detailed analysis of temperature gradients and heat diffusion patterns aids in the measurement of thermal conductivity values along the sample's different crystallographic directions. The directional bonding characteristics and inherent crystallographic structure of the alloy account for the inplane thermal conductivities calculated from experimental thermal measurements. The laser-spot thermography method has proven to be an effective tool for mapping the material's thermal conductivity anisotropy with high sensitivity and high spatial and temporal resolution. The investigation into the anisotropy of the material provides an insight into heat flow in the structure and helps in optimizing the design and overall performance of the material system. T2 - 17th International Conference on Quantitative InfraRed Thermography 2024 CY - Zagreb, Croatia DA - 01.07.2025 KW - Infrared thermography KW - Anisotropy KW - Laser-spot thermography PY - 2024 UR - https://nbn-resolving.org/urn:nbn:de:kobv:b43-653877 DO - https://doi.org/10.21611/QIRT-2024-075 SP - 1 EP - 6 PB - QIRT Council AN - OPUS4-65387 LA - eng AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - CONF A1 - Hassenstein, Christian T1 - Automatisierte Bahnplanung für robotergestützte Ultraschallprüfung mit Arrayprüfköpfen N2 - In der automatisierten Ultraschallprüfung von Komponenten mit komplexen Oberflächengeometrien werden zur Führung des Prüfkopfes zunehmend 6-Achsen-Roboter erprobt. Diese stellen die notwendige Automatisierbarkeit und Flexibilität bereit, um die lokal senkrechte Einschallung sicherzustellen. Durch den Einsatz von linearen Arrays und bildgebenden Verfahren können die Bilder oder die daraus extrahierten Merkmale zu einer Rekonstruktion in 3D zusammengesetzt werden. Die Anforderungen an die Prüfbahnen für die bildgebende Array-Ultraschallprüfung gehen dabei über konventionellen Bahnplanungsprogramme hinaus. Es wird ein Prozess vorgestellt, der Roboterbahnen auf der Grundlage des 3D-Modells von Körpern mit doppelt gekrümmter Oberfläche unter Berücksichtigung der Prüfparameter erzeugt. Hierbei wird zum einen die senkrechte Prüfkopfstellung und zum anderen eine optimale Abdeckung der Oberfläche realisiert. Dabei wird die lokale Oberflächengeometrie beachtet, da diese das Reflexionsverhalten beeinflusst und sich daher auf die optimale Verteilung und Orientierung der Prüfpositionen auswirkt. Damit einhergehend erfolgt eine Ablösung von konventionellen Konzepten, die auf linearen Prüfbahnen basieren, welches spannende neue Prüfstrategien eröffnet. T2 - DGZfP-Jahrestagung 2024 CY - Osnabrück, Germany DA - 06.05.2024 KW - Ultraschallprüfung KW - Phased array KW - Automatisierung KW - NDT 4.0 PY - 2024 AN - OPUS4-60590 LA - deu AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - CONF A1 - Kunji Purayil, Sruthi Krishna T1 - Anisotropy investigation of a single crystal superalloy using laser-spot infrared thermography N2 - Thermal property investigation of anisotropic materials such as single crystal superalloys are still in interest of practical and fundamental reasons but remains challenging using conventional testing methods. In this study, a single crystal superalloy is tested using laser-spot thermography, and its thermal anisotropy is investigated. Determining anisotropic thermal conductivity at microscopic scales is challenging, as it appears isotropic at the macroscopic scale. Infrared thermography is one of the best-known techniques for measuring material heat transfer properties and facilitating visualization of temperature distribution through the specimen. The proposed study uses the active thermography method of laser-spot infrared thermography, in which a laser spot is focused onto the sample surface and the thermal response is captured from the surface of the specimen with an infrared camera. A detailed analysis of temperature gradients and heat diffusion patterns aids in the measurement of thermal conductivity values along the sample's different crystallographic directions. The directional bonding characteristics and inherent crystallographic structure of the alloy account for the in-plane thermal conductivities calculated from experimental thermal measurements. The laser-spot thermography method has proven to be an effective tool for mapping the material's thermal conductivity anisotropy with high sensitivity and high spatial and temporal resolution. The investigation into the anisotropy of the material provides an insight into heat flow in the structure and helps in optimizing the design and overall performance of the material system. T2 - 17th Quantitative InfraRed Thermography Conference (QIRT) CY - Zagreb, Croatia DA - 01.07.2024 KW - Infrared Thermography KW - NDT KW - Laser KW - Single crystal superalloy KW - Anisotropy PY - 2024 AN - OPUS4-60663 LA - eng AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - CONF A1 - Hirsch, Philipp Daniel T1 - Robotergestützte 3D-Scans und Laserthermografie zur Prüfung an komplexen Bauteilen auf Risse N2 - Der Vortrag stellt innovative Ansätze zur Automatisierung von Prüfprozessen durch den Einsatz von Robotik und Laserthermografie vor. Im Fokus steht die robotergestützte Laserthermografie zur Identifikation und Analyse von Rissen in komplexen Bauteilen. Diese Methode ermöglicht eine vollständig automatisierte Rissprüfung, die ohne manuelle Arbeitsschritte und chemische Prüfmittel auskommt und damit eine effiziente Alternative zur klassischen Farbeindringprüfung darstellt. Zusätzlich wird ein automatisiertes 3D-Scanning mittels Linienscanner präsentiert, das eine präzise Rekonstruktion der Bauteilgeometrie erlaubt. Dies ermöglicht die adaptive Korrektur von Abweichungen in der Bauteilaufnahme und bildet die Grundlage für eine flexible Bahnplanung bei Bauteilverformungen. Ein weiterer Schwerpunkt ist die automatisierte Rückprojektion der detektierten Risse auf die Bauteiloberfläche. Diese Technik erlaubt nicht nur eine präzise Lokalisierung, sondern auch eine detaillierte geometrische Analyse der Risse. Durch die Kombination von robotergestützter Laserthermografie, hochpräzisem 3D-Scanning und intelligenter Rückprojektion ergeben sich neue Möglichkeiten für die zerstörungsfreie Prüfung komplexer Bauteile und die Erweiterung potenzieller Anwendungsfelder. T2 - Jahrestagung der Deutschen Gesellschaft für Zerstörungsfreie Prüfung (DGZfP) 2024 CY - Osnabrück, Germany DA - 06.05.2024 KW - ZFP4.0 KW - Automatisierung KW - Roboter KW - Laser KW - Rissprüfung KW - Thermografie PY - 2024 AN - OPUS4-62494 LA - deu AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER -