Ingenieurwissenschaften und zugeordnete Tätigkeiten
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The aim of this work is to illustrate the contribution of signal processing techniques in the field of Non-Destructive Evaluation. A component’s life evaluation is inevitably related to the presence of flaws in it. The detection and characterization of cracks prior to damage is a technologically and economically significant task and is of very importance when it comes to safety-relevant measures. The Laser Thermography is the most effective and advanced thermography method for Non-Destructive Evaluation. High capability for the detection of surface cracks and for the characterization of the geometry of artificial surface flaws in metallic samples of laser thermography is particularly encouraging. This is one of the non- contacting, fast and real time detection method. The presence of a vertical surface breaking crack will disturb the thermal footprint. The data processing method plays vital role in fast detection of the surface and sub-surface cracks.
Currently in laser thermographic inspection lacks a compromising data processing algorithm which is necessary for the fast crack detection and also the analysis of data is done as part of post processing. In this work we introduced a raw data based image processing algorithm which results precise, better and fast crack detection. The algorithm we developed gives better results in both experimental and modeling data. By applying this algorithm we carried out a detailed investigation Variation of thermal contrast with crack parameters like depth and width. The algorithm we developed is applied for various surface temperature data from the 2D scanning model and also validated credibility of algorithm with experimental data.
In-line laser thermography for crack detection at elevated temperature: A Numerical modeling study
(2016)
The detection and characterization of cracks prior to damage is a technologically and economically highly significant task and is of very importance when it comes to safety-relevant structures. The evaluation of a components life is closely related to the presence of cracks in it. Laser thermography has already high capability for the detection of surface cracks and for the characterization of the geometry of artificial surface flaws in metallic samples. Crack detection in metallic samples at high temperature is highly significant in present manufacturing scenario. During the casting process of billets, surface cracks form, due to the suboptimal cooling rates. These cracks reduce value of the billet and must be removed using machining process after cooling. This secondary process increases cost of manufacturing. In this work we developed a heat transfer model for laser thermography to study the thermal contrast variation with increase in surface temperature using finite element method (FEM). Here we are mainly concentrating the capability of the scanning laser thermography in crack detection which are in elevated temperature and numerical modeling study of thermal contrast variation of crack with respect increase in metal surface temperature. This study is important to prove the capability of laser thermography for crack detection in elevated temperature. Since we are using High power CW Laser to local heating of the metal surface which can give relatively high thermal contrast even at elevated temperature compare to other heating source. Here we are modeled and simulated 2D laser scanning across a surface breaking crack and developed an algorithm to produce the vicinity of crack. The algorithm we developed applied for various surface temperature data. And validated the credibility of the algorithm with experimental data.
Spot welding is one of the most important joining technologies, especially in the automotive industry. Hitherto,the quality of spot welded joints is tested mainly by random destructive tests. A nondestructive testing technique offers the benefit of cost reduction of the testing procedure and optimization of the fabrication process, because every joint could be examined. This would lead to a reduced number of spot welded joints, as redundancies could be avoided. In the procedure described here, the spot welded joint between two zinc-coated steel sheets (HX340LAD+Z100MB or HC340LA+ZE 50/50) is heated optically on one side. Laser radiation and flash light are used as heat sources. The melted zone, the so called “weld nugget” provides the mechanical stability of the connection, but also constitutes a thermal bridge between the sheets. Due to the better thermal contact, the spot welded joint reveals a thermal behavior different from the surrounding material, where the heat transfer between the two sheets is much lower. The difference in the transient thermal behavior is measured with time resolved thermography. Hence, the size of the thermal contact between the two sheets is determined, which is directly correlated to the size of the weld nugget, indicating the quality of the spot weld. The method performs well in transmission with laser radiation and flash light. With laser radiation, it works even in reflection geometry, thus offering the possibility of testing with just one-sided accessibility. By using heating with collimated laser radiation, not only contactfree, but also remote testing is feasible. A further convenience compared to similar thermographic approaches is the applicability on bare steel sheets without any optical coating for emissivity correction. For this purpose, a proper way of emissivity correction was established.