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Reliability of NDT is affected by human factors, which have thus far received the least amount of attention in the reliability assessments. With increased use of automation, in terms of mechanised testing (automation-assisted inspection and the corresponding evaluation of data), higher reliability standards are believed to have been achieved. However, human inspectors, and thus human factors, still play an important role throughout this process and the risks involved in this application are unknown. The aim of this study was to explore for the first time the risks associated with mechanised NDT and find ways of mitigating their effects on the inspection performance. Hence, the objectives were to identify and Analyse potential risks in mechanised NDT and devise measures against them. To address those objectives, a risk assessment in form of a Failure Modes and Effects Analysis (FMEA) was conducted. This analysis revealed potential for failure during both the acquisition and evaluation of NDT data that could be assigned to human, technology, and organisation. Since the existing preventive measures were judged to be insufficient to defend the system from identified failures, new preventive measures were suggested.
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.
Machine learning based multi-sensor fusion for the nondestructive testing of corrosion in concrete
(2020)
Half-cell potential mapping (HP) is the most popular non-destructive testing method (NDT) for locating corrosion damage in concrete. It is generally accepted that HP is susceptible to environmental factors caused by salt-related deterioration, such as different moisture and chloride gradients. Additional NDT methods are able to identify distinctive areas but are not yet used to estimate more accurate test results. We present a Supervised Machine Learning (SML) based approach to data fusion of seven different signal features to obtain higher quality information. SMLs are methods that explore (or learn) relationships between different (sensor) data from predefined data labels. To obtain a representative, labelled data set we conducted a comprehensive experiment simulating the deterioration cycle of a chloride exposed device in the laboratory. Our data set consists of 18 measurement campaigns, each containing HP, Ground Penetrating- Radar, Microwave Moisture and Wenner resistivity data. We compare the performance of different ML approaches. Many outperform the best single method, HP. We describe the intrinsic challenges posed by a data-driven approach in NDT and show how future work can help overcome them.
Learned block iterative shrinkage thresholding algorithm for photothermal super resolution imaging
(2022)
Block-sparse regularization is already well known in active thermal imaging and is used for multiple-measurement-based inverse problems. The main bottleneck of this method is the choice of regularization parameters which differs for each experiment. We show the benefits of using a learned block iterative shrinkage thresholding algorithm (LBISTA) that is able to learn the choice of regularization parameters, without the need to manually select them. In addition, LBISTA enables the determination of a suitable weight matrix to solve the underlying inverse problem. Therefore, in this paper we present LBISTA and compare it with state-of-the-art block iterative shrinkage thresholding using synthetically generated and experimental test data from active thermography for defect reconstruction. Our results show that the use of the learned block-sparse optimization approach provides smaller normalized mean square errors for a small fixed number of iterations. Thus, this allows us to improve the convergence speed and only needs a few iterations to generate accurate defect reconstruction in photothermal super-resolution imaging.
LIBS‐ConSort: Development of a sensor‐based sorting method for construction and demolition waste
(2023)
AbstractA joint project of partners from industry and research institutions approaches the challenge of construction and demolition waste (CDW) sorting by investigating and testing the combination of laser‐induced breakdown spectroscopy (LIBS) with near‐infrared (NIR) spectroscopy and visual imaging. Joint processing of information (data fusion) is expected to significantly improve the sorting quality of various materials like concrete, main masonry building materials, organic components, etc., and may enable the detection and separation of impurities such as SO3‐cotaining building materials (gypsum, aerated concrete, etc.)Focusing on Berlin as an example, the entire value chain will be analyzed to minimize economic / technological barriers and obstacles at the cluster level and to sustainably increase recovery and recycling rates.The objective of this paper is to present current progress and results of the test stand development combining LIBS with NIR spectroscopy and visual imaging. In the future, this laboratory prototype will serve as a fully automated measurement setup to allow real‐time classification of CDW on a conveyor belt.
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.
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.
Thermographic photothermal super resolution reconstruction enables the resolution of internal defects/inhomogeneities below the classical limit, which is governed by the diffusion properties of thermal wave propagation. Based on a combination of the application of special sampling strategies and a subsequent numerical optimization step in post-processing, thermographic super resolution has already proven to be superior to standard thermographic methods in the detection of one-dimensional defect/inhomogeneity structures. In our work, we report an extension of the capabilities of the method for efficient detection and resolution of defect cross sections with fully two-dimensional structured laser-based heating. The reconstruction is carried out using one of two different algorithms that are proposed within this work. Both algorithms utilize the combination of several coherent measurements using convex optimization and exploit the sparse nature of defects/inhomogeneities as is typical for most nondestructive testing scenarios. Finally, the performance of each algorithm is rated on reconstruction quality and algorithmic complexity. The presented experimental approach is based on repeated spatially structured heating by a high power laser. As a result, a two-dimensional sparse defect/inhomogeneity map can be obtained. In addition, the obtained results are compared with those of conventional thermographic inspection methods that make use of homogeneous illumination. Due to the sparse nature of the reconstructed defect/inhomogeneity map, this comparison is performed qualitatively.
In this work, we present a novel approach to photothermal super resolution based thermographic resolution of internal defects using two-dimensional pixel pattern-based active photothermal laser heating in conjunction with subsequent numerical reconstruction to achieve a high-resolution reconstruction of internal defect structures. With the proposed adoption of pixelated patterns generated using laser coupled high-power DLP projector technology the complexity for achieving true two-dimensional super resolution can be dramatically reduced taking a crucial step forward towards widespread practical viability. Furthermore, based on the latest developments in high-power DLP projectors, we present their first application for structured pulsed thermographic inspection of macroscopic metal samples. In addition, a forward solution to the underlying inverse problem is proposed along with an appropriate heuristic to find the regularization parameters necessary for the numerical inversion in a laboratory setting. This allows the generation of synthetic measurement data, opening the door for the application of machine learning based methods for future improvements towards full automation of the method. Finally, the proposed method is experimentally validated and shown to outperform several established conventional thermographic testing techniques while conservatively improving the required measurement times by a factor of 8 compared to currently available photothermal super resolution techniques.
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.