Wissenschaftliche Artikel der BAM
The digital photography has almost completely substituted the film photography. The film replacement is also fast progressing in medical X-ray radiography. This process is slower in NDT and especially in Europe. Reasons for the hesitating change to digital radiography (RT-D) in NDT are the necessary time for adoption of standards and the conservative request for film RT by auditors and NDT managers for applications in large plants and at construction areas. The fast serial inspection for small castings is already almost completely dominated by RT-D due to the cost effective short exposure and interpretation times. Standards were developed in parallel at CEN, ISO, ASTM and ASME. Unfortunately, the standard practices are different and the requirements on image quality and useable hardware are different too. The first standard series on Computed Radiography were developed and published by CEN and ASTM in 2005. Harmonized classification and qualification standards are available but the published practices are different. ASTM has developed the first standards for application of Digital Detector Arrays (DDA) in 2010. The first digital RT ISO standard practice is ISO 17636-2 (2013), which describes the practice for application of DDAs and Imaging Plates for weld inspection. At the first time this standard provides requirements for the selection of suitable hardware. Minimum image quality requirements are specified in analogy to film radiography and 3 Compensation Principles are defined to enable the application of a wider range of digital detectors. A comparison of the different international digital RT standards is given and first experiences with ISO 17636-2 are discussed. New standards on RT wall thickness and corrosion measurements (EN 16407, film and digital) have been developed recently.
Critical parts in aircraft manufacturing such as stringers are very commonly used in modern aircraft structures to resist the compressive loads caused by the aerodynamic effects. They are generally made-up of thin aluminium (Al) metal sheets and are one of the key components in the aircraft wings. Any defects in the stringer leads to weakening of the stiffness of the whole wing structure and consequently, failures may occur. Hence, the structural integrity of the stringers should be evaluated using reliable non-destructive testing (NDT) methods. Due to the complex shaped structure of the stringer, the one-sided access NDT method such as X-ray backscatter technique is more preferable for the non-destructive imaging. In this paper, we present a new X-ray backscatter technique to image the internal sections of the stringer with only a single-sided access. The whole object was inspected by changing the viewing direction of the X-ray backscatter camera. For the first time, the X-ray backscatter measurements were conducted using high-energy (> 0.5MeV) X-rays and proved the applicability of the present technique to inspect thick carbon-fiber laminated components. In order to improve the inspection time and image quality of the backscatter image, we used high-resolution (180ìm) digital detector arrays (DDAs). At the end, important applications of the presented X-ray backscatter technique to the aerospace industry are discussed.
In this contribution, we present a dual high-energy X-ray imaging technique for cargo container inspection using the 'spectral high-energy X-ray attenuation method'. This method is based on attenuation of continuous highenergy spectra. The developed experimental technique consists of a betatron as high-energy (up to 7.5 MeV) X-ray source and a matrix detector with high spatial resolution (400 ìm) for digital X-ray imaging. In order to evaluate the material discrimination capability using dual high-energy X-ray imaging, a test specimen is proposed, comprising step wedges of different low and high atomic number (Z) materials. The selected X-ray spectra for the dual-energy experiments correspond to 3 MV and 7.5 MV acceleration potential of the betatron. We evaluated the ratio between low- and high-energy X-ray attenuation coefficients quantitatively based on simulated poly-energetic high-energy X-ray source spectra and the detector sensitivity using the 'analytical Radiographic Testing inspection simulation tool' (aRTist) developed at BAM. The simulated effective attenuation coefficients are compared with corresponding experimental results in order to establish a method for identification of low- and high-Z materials in the container. Finally, important applications of the proposed technique in the context of aviation security are discussed.
Measurement of spontaneous magnetic stray field signals has been reported to be a promising tool for capturing macro-scale information of deformation states, defects and stress concentration zones in a material structure. This paper offers a new method for self-magnetic leakage field detection using a magneto-optical (MO) hand-held microscope. Its sensor has a dynamic field range between ±0.05 and ±2 kA/m and a lateral optical resolution of approx. 10 µm. We examined flat tensile test specimens of metastable austenitic steel AISI 304. Static tensile tests were repeatedly interrupted at various predetermined states of strain and the magnetic information was measured by the MO system. Comparative measurements using a high-precision magnetic field GMR-sensor, verify the outstanding capability of the MO microscope regarding spatial resolution of magnetic fields.
The canister for the permanent storage of spent nuclear fuel used by SKB in Sweden consists of a cast iron insert surrounded by a five centimetre thick shell of copper. It is a safety critical component and in order to secure long-term structural integrity non-destructive methods are used to inspect 100% of the volume of each canister, before it is disposed of in the repository. One of the critical components that requires inspection is a sealing weld, joining the copper tube and the lid. The friction stir weld is inspected using an ultrasonic phased array system. The area of the weld is inspected with several inspection channels with different angles and varying coverage. To make sure that no defects that might occur in the weld are overseen, the reliability of the inspection must be quantified. The reliability of NDT is usually quantified with the probability of detection curves. The influence of the parameters that might influence the POD of the flaws in the weld is investigated analysing the experimental results, as well as with a help of a numerical simulation of the inspection.
Currently at Deutsche Bahn (DB) ultrasonic inspections in maintenance procedures for wheelset axles with a bore hole are, to the greatest possible extent, carried out using automated ultrasonic inspection system. Although the acceptance levels are in accordance with DIN 27201 part 7, the testing results have shown in recent years that in the case of true indications, the effective defect sizes were far below the level of acceptance. Due to this experience it can be assumed that the automated ultrasonic inspection systems are testing substantially more sensitively than required. This increased sensitivity leads to an increase in false indications, generally resulting in the unnecessary demounting of wheelsets. In Research cooperation between Federal Institute for Materials Research and Testing (BAM) and DB the effective flaw detection sensitivity of existing automated ultrasonic inspection system will be determined and the true/false indication ratio optimised. Through systematic investigations with the Probability of Detection method on the existing automated ultrasonic inspection system the results could be directly applied to the optimisation of existing ultrasonic inspections of wheelset axles with a bore hole in maintenance procedures and the level of reliability can be considerably increased.
Since decades the evaluation of flaw indications on radiographs from welds or castings are based on well accepted reference film catalogues from organizations like IIW (weldments), ASTM (castings) or DGZfP (D5 recommendation on heavy steel castings). Today, the transformation of classical film radiography to the digital world is in full progress. Some ASTM standards do not permit the evaluation of digital radiographs in reference to film catalogues. Therefore, these reference film catalogues have to be converted into the digital age too. BAM is supporting this transition by high definition film scanning. The result is a corresponding reference image catalogue. The different standard organizations selected different ways to distribute the digital data. ASTM used high definition film scanning at 10 μm pixel size and distribution of a huge amount of high-res data via DVD. The user sub-samples these high-res data during catalogue import to the resolution of his system. The comparison is done by synchronized image viewing on the computer work station. IIW recently decided to distribute their ISO 5817 reference images installed on tablets, which are used for image viewing too. The tablet image has to be compared with the digital image on the system monitor. DGZfP transformed their D5 reference radiographs into a PDF for monitor viewing. This is the simplest and cheapest solution, but still allows the full usage of the catalogue in the digital era. The status of ongoing work in progress will be discussed.
Analyzing the reliability of non-destructive tests using the modular modell - a practical approach
(2016)
Non-destructive testing is an important tool to guarantee the safety of railway traffic.
The infrastructure with tracks, switches and sleepers is regularly tested, the
locomotives and wagons with their wheels, bogies and axles as well. Many years of experience and some events lead in Germany to a good practice in testing the railway components. Now, European authorities are drafting a system of common requirements and standards for the European Railway Market. The German practice combines an intensive training of the NDT-personnel including sufficient time for practical exercises with organizational measures of the companies, responsible for rolling stock and infrastructure. Through the example of UT-testing of railway axles it will be shown, how training and organizational measures influence the reliability of such testing.
The usefulness and purpose of evaluating nondestructive testing (NDT) systems and their capabilities has changed in the last decade. The conventional method of simply applying a familiar statistical algorithm to say whether the system is usable for the tasks is history.
Nowadays, multiple parameter methods which describe the probabilities of detection (POD) of different systems or real defects need new characteristics and a broader variety of statistical models to describe the true system behaviour. The appraisal of the NDT system involves diverse departments within a company (engineering, NDT-operators, and statisticians), but is, at the same time, more needed and requested than in the past. In this article, an approach is discussed in which professionals from different fields worked well together, accomplishing cost-intensive metallographic studies in correlation with well-understood physical behaviour of NDT-methods as well as deep-discussed mathematical methods to create a holistic evaluation of the technical reliability for a specific radiographic testing (RT) equipment. The first part of the publication will show the comparison between metallographic grinding and the RT indications. An essential innovation over past evaluation methods was the use of a multi-scale smoothing algorithm, which describes physical parameters, which were not used in evaluation like the POD in this way in the past.
In the second part the statistical requirements for the POD take the focus. It can often be hard to make significant statements; especially in the case where only a small amount of data is available. The combination of data and the use of knowledge from simulations are essential. One possible solution will be shown for the RT evaluation. The methodology is used for evaluating the digital RT system for the inspection of electron-beam welds, which was method considered to seal the Finnish copper canisters for the final deposit of spent nuclear fuel.
Ultrasonic phased array is, currently, the technology which is being applied as the solution to a lot of inspection problems. The perceived benefits are seen to be worth the outlay on equipment and specialised personnel. Yet, there is a source of knowledge, freely available, which can also deliver immediate benefits, through more reliable inspection results, and consequently increased client confidence, but which is largely ignored by the greater part of the NDT community. This talk will review the latest Human Factors knowledge and provide practical illustrations of how companies can use it to improve their competitive edge.