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Eingeladener Vortrag
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Zusammenfassung
Der Prototyp einer Flachröntgenröhre mit einer maximalen Röntgenenergie von 240kV (600W) und einer Brennfleckgröße von 0,4 * 0,4 mm nach DIN EN 12543 wird vorgestellt. Das Design dieser Flachröntgenröhre mit geringer Aufbauhöhe ist in Metall-Keramik-Technik ausgeführt. Die Beschleunigungsstrecke Katode-Anode ist senkrecht zur Haubenachse ausgeführt. Die Röhre ist als bipolares System aufgebaut. Kleine Durchmesser der Hochspannungskabel verringern das Gewicht und resultierende Kraftmomente bei der manuellen Manipulation sowie beim Verfahren in einem mechanisierten System. Der Targetwinkel beträgt 6° und bewirkt eine höhere Brillianz der Röntgenstrahlung. Die Geometrie des Strahlenaustrittsfensters (Emissionsfenster) ist in Fächerstrahlgeometrie zur tomografischen Prüfung ausgelegt.
During the second European-American Workshop on NDE Reliability, September 99 in Boulder, the term NDE reliability was defined as the degree that an NDT system is capable of achieving its purpose regarding detection, characterization and false calls. The most common but also most expensive - way to determine this degree of capability in e.g. defect detection is to make just a performance demonstration using realistic test samples and to count the correct detections and false calls. For a more efficient way of reliability evaluation we propose to decompose the system into main modules e.g. according to the reliability formula set up on the first workshop: into f(IC) a function of IC the intrinsic capability, determined by the physics and the technique of the NDE method representing an ideal upper bound of the reliability and g(AP) a function of AP the industrial application factor like surface state or limited access to a component in general diminishing the ideal capability and finally h(HF) the function of the human factor which is in general also diminishing the ideal capability. The workshop proposed a rather plain mathematical shape for the formula R = f(IC) g(AP) h(HF) which should be considered merely as a philosophical expression but not as exact mathematical formula to be applied for evaluation of e.g. POD data. We propose to decompose the NDE system into modules in terms of functions of IC, AP and HF if appropriate or additional ones if necessary and then to analyze the mutual relationships of the terms via fault tree analysis. Finally the total reliability of the system is composed of the reliability of the subsystems via the rules of statistical systems theory.
First trials for this approach of data analysis will be presented via examples from NDE systems in the aerospace industry.
Mechanisierte Durchstrahlungsprüfung - Innovative Techniken zur Bewertung von Rundschweißnähten
(2001)
One of the most important tasks for in-service weld inspection of Circumferential welds is the detection of planar defects and its sizing. The information about the shape, length and depth of defects like cracks and lack of fusion can be measured quantitatively with a mechanised system for manipulation of X-ray source and line camera. The well adjusted manipulation system allows the testing of pipes with a
diameter between 176 mm and 500 mm. The system is based on several modules, which can be adjusted to the testing problem. The energy of the X-ray tube amounts 225 keV. The pixel resolution of the line camera is 50µm for 2048 pixels per line. The camera and the X-ray tube are separated on the pipe by an angle of 180°. They are moved line by line around the circumference to acquire the radiometric image.
The basic problem of radiography as well as of the radiometric scan technique is the dependence of the measured crack contrast on the radiation direction in relation to the crack location. Only parallel transmission to the crack plane provides sufficient contrast. This requires application of the multi-angle technique. The developed scanner enables modification of the radiation direction. It is possible to set up the system for a special inspection of side wall flaws. Scanning the weld under different angles provides multi -angle projections which improve the probability of detection for planar inhomogeneities in the material like cracks and lack of fusion.
Furthermore, the multi-angle technique provides enough information for a 3D-reconstruction of the weld structure. New methods of digital laminography and tomosynthesis permit the measurement of the shape and depth of the indications.
The developed system, which is applicable for mobile in service inspection, is presented together with the results of the measurement techniques like planar scan, coplanar laminography, tomosynthesis and cross-sectional planar tomography.
The quantitative measurement of kind, positions and diameters of steel reinforce ments in building constructions is a typical inspection problem in civil engineering. A classical solution is the combination of film radiography with the multi angle technique and graphical backprojection. New digital detectors reduce the exposure time and allow the application of stereo radiography and computed laminography as routine applications.
The computed laminography allows fast and effectively the determination of the depth of reinforcements in concrete or masonry. A selected area of the steel re-bar structure is penetrated by gamma-rays from different angles of incidence (multi angle-technique) with a Co-60-source. Instead of a radiographic film phosphor imaging plates were used as a new digital medium for filmless radiography. A 3D-image of the measured region of interest is reconstructed from the digitised projections of a test block. The reconstruction is based on special tomosynthesis algorithms which need few projections only.
Radiographic techniques were uses in completion to other techniques like radar, electromagnetic alternating field inspection to examine the structure of different buildings. Experiences of inspections of historical buildings, ancient marble structures and a bridge girder are presented where different levels of radiography were applied.
Tomographic visualization, inspection and control of thick pipe walls by restricted X-ray data
(2004)
Tomographic 3D-Radiometry for the visualisation and measurement of the defects of Girth Seams
(2006)
Mobile Tomographic Computer Aided Radiometry (TomoCAR) is based on the mechanical position control of an X-ray tube in front of an object and the application of a Digital Detector Array (DDA) behind it. Several hundred radiometric projections in small angle steps are acquired during the controlled movement of the X-ray tube along a preselected way. The tomographic or laminographic reconstruction allows the three-dimensional (3D) representation of flaws. A specially designed radiometric detector array with small internal unsharpness and high image contrast was used for visualization and sizing of planar and volumetric defects in austenitic welds in nuclear power plants. A German pilot study was successfully performed on the basis of the European network of inspection and qualification (ENIQ) guidelines. This was the precondition for several applications of TomoCAR in nuclear power stations in Germany and Switzerland.
A versatile computed tomography (CT) system was developed on basis of the TomoCAR design for in situ inspection of large aircraft components under production conditions. A gate based planar computed tomograph was constructed and tested for inspection of the integrity of CFRP stringers, embedded in aircraft fibre composite shells. A probability of crack visibility >90% could be determined.
Hot crack assessment during production and processing of metallic materials is an essential prerequisite for the safety of welded structures. The hot cracking investigations presented here were carried out as part of a study aimed at the development of Cr/Ni low transformation temperature filler materials. Low transformation temperature alloys open up the possibility for welding high strength steels. The externally loaded Modified Varestraint Transvarestraint hot cracking test was employed in the experiments described. The hot cracking resistance was evaluated with the help of light microscopy applied at the specimen surface. The proportionality between hot cracking susceptibility and Cr/Ni alloy content was explained by the altered solidification kinetics and by the enlarged solidification interval. The internal crack paths and the three-dimensional structure of the crack net in the material volume were examined using X-ray computer tomography. The total crack lengths for different material depths and circumjacent rectangular volumes, respectively, were be determined. An increasing hot cracking susceptibility with increasing Cr/Ni alloy content was also be established for the specimen volume.
This paper presents the progress of successful location of grouting faults in tendon ducts with ultrasonic imaging. The examples were obtained in the research group FOR 384 funded by DFG (German Research Foundation). The co-operation of experimental research and modeling allowed imaging and identification of grouted and ungrouted areas of tendon ducts (including strands) in a large test specimen (40 m²). In addition to the criteria for indicating grouting faults in post-tensioned ducts known until now the phase evaluation of reflected ultrasonic pulses is described. Experiments and modeling of wave propagation are presented for reflections at metal plates in concrete (thickness range 0.5 mm to 40 mm) and for tendon ducts including strands.
The main part of the progress was achieved by automated measurements using dry contact transducers, 3D-SAFT reconstruction including phase evaluation and modeling considering wave propagation for typical elastic parameters and exact experimental site conditions. The results for shear waves as well as for pressure waves are compared in the frequency range from 50 kHz to 120 kHz.
Radiografische und tomografische Verfahren zur Bestimmung der Wanddicke mittels Röntgenabsorption
(2007)
Tomographical Computer Aided Radiology (TomoCAR) is based on the mechanical position control of
an X-ray tube in front of a welding seam and the application of a planar array detector behind it. Several hundred
radiometric projections in small angle steps are acquired. The tomographical reconstruction allows the three-dimensional
(3D) representation of the defects. A new radiometric array detector system with a small internal
unsharpness and high image contrast is used for the 2- and 3-dimensional visualization and sizing of planar defects
with a defect opening of less than 100 µm. This detector is based on a CMOS-flat panel with a direct converting
CdTe-single crystal layer. The small design allows the application of the mobile testing equipment for mechanized
X-ray inspection in industrial plants. The physical pixel size of the detector amounts to 0,1x0,1 mm². Nevertheless,
this system yields a better spatial resolution than indirect converting detectors (e.g. cameras with fluorescence
layers of Gd2O2S). It allows the reliable detection of planar defects with openings far below the detector pixel size
by subpixel resolution.
'TomoCAR' is qualified at present in the context with a German pilot study following to the ENIQ guidelines for
the employment within the nuclear power industry.
TomoCAR - Tomographische 3D-Radiometrie zur Visualisierung und Vermessung von Schweißnahtfeldern
(2005)
Tomographie 3D-Radiometry for the Visualisation and Measurement of the Defects of Girth Seams
(2006)
Zur Durchstrahlung großer, dichter Objekte reichen die Energien, die mit normalen Röntgenröhren erzielt werden können, ab gewissen Schichtdicken nicht mehr aus. Als hochenergetische Strahlenquellen stehen Kobalt-60 und Elektronenbeschleuniger zur Verfügung. Als Einschränkung der Hochenergieradiographie ist der geringere Kontrast besonders beim Vorhandensein leichterer Objekte umgeben von Körpern bestehend aus schweren Elementen anzusehen. Es ist daher zu erwarten, dass Objekte aus organischen Substanzen hinter dicken Schwermetallwänden oder in Bohrungen von Metallblöcken schwer zu erkennen sind. Im Gegensatz zu einem Gammastrahler wie Kobalt-60 mit den beiden Spektrallinien um 1,3 MeV besitzt die Bremsstrahlung aus einem Beschleuniger einen wesentlichen Anteil an niederenergetischer Strahlung, der fließend zu höheren Energien übergeht. Es wird hier untersucht, welche Signaturen von leichten Materialien in einer Umgebung aus Schwermetall bis zu welcher Dicke und bis zu welchem Komplexizitätsgrad erkennbar sind. Mit einem Betatron (JME X-ray Betatron 7,5 MeV) und einem Matrixdetektor (Perkin Elmer XRD 1621) wurden Aufnahmen von unterschiedlichen leichten Objekten angefertigt, die zunehmend in eine Umgebung aus Schwermetallen gestellt wurden. Mit unterschiedlichen Energieeinstellungen wurde untersucht, inwieweit eine Materialerkennung hinter welcher Abschirmung möglich ist. Die experimentellen Ergebnisse werden mit Simulationen verglichen, die mit einer Software zur Modellierung von Durchstrahlungsverfahren (aRTist) erzeugt wurden. Dabei wird dem Problem der Aufhärtung bei Anwendung von Bremsstrahlung Rechnung getragen. Die Ergebnisse können sowohl zur Erkennung von Fremdkörpern in Maschinen oder Pumpen als auch zur Überprüfung von Frachtladungen im Bereich der öffentlichen Sicherheit und bei Zollkontrollen dienen.