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The General Guidance in the Swedish regulations state that the safety assessment for a final repository for spent nuclear fuel should be 1 million years after closure. SKB developed the KBS-3 method, according to which the spent nuclear fuel is protected by three barriers. It is encapsulated in canisters with a diameter of 1 metre and a length of 5 metres. The canister consists of a cast iron insert surrounded by a 5 centimetre thick shell of copper. The canisters are disposed in the bedrock at a depth of about 500 meters surrounded by bentonite clay. In order to assess the safety over this extremely long period, an extensive quality control programme is applied to the canisters before deposit. In this programme, the use of
non-destructive testing (NDT) is vital. The safety assessment of the canister in turn places high demands on the coverage, detectability, and reliability of the applied NDT inspections of the canister parts, i.e. cast iron insert, copper base, tube and lid, and the copper friction stir welds (FSW). This paper presents the extensive full-scale inspection development programme that runs at the Canister Laboratory in Oskarshamn (Sweden). In order to fulfil the high demands, phased array ultrasonic inspection techniques are developed using practical trials aided by ultrasonic modelling. The techniques apply, for example, different frequencies, inspection angles, focus depths, and both longitudinal and shear waves. Increased inspection reliability of the FSW is achieved by applying digital X-ray technique using a 9 MeV linear accelerator and a line detector. To complete the coverage, complementary surface inspections methods, i.e. eddy current array, magnetic flux sensor techniques and magnetic particle inspection, are applied. The canister safety assessment was the driving force to include reliability studies during the NDT development. Initially, the technical reliability was considered, resulting in development of advanced POD models (probability of detection). In combination with human factors studies, these models were implemented as tools in the development of the NDT techniques. Human factors studies were also applied to improve the inspection procedures to be more user-friendly enabling reliable inspections.
The round robin test investigated the reliability users can expect for AlSi10Mg additive manufactured specimens by laser powder bed fusion through examining powder quality, process parameter, microstructure defects, strength and fatigue. Besides for one outlier, expected static material properties could be found. Optical microstructure inspection was beneficial to determine true porosity and porosity types to explain the occurring scatter in properties. Fractographic analyses reveal that the fatigue crack propagation starts at the rough as-built surface for all specimens. Statistical analysis of the scatter in fatigue using statistical derived safety factors concludes that at a stress of 36.87 MPa the fatigue limit of 107 cycles could be reached for all specimen with a survival probability of 99.999 %.
Classical film radiography is a well-established NDT technique and it is most commonly used for testing weld seams and corroded pipes e.g. in oil and gas industry or in nuclear power plants. In the course of digitization, digital detector arrays (DDA) are finding their way into industrial applications and are replacing film radiography step by step. This study deals with the latest generation of DDAs, the photon counting and energy resolving detectors (PCD), and their characteristics compared to charge integrating detectors (CID). No matter which technology to use, radiography still lacks a general issue: A three-dimensional object is projected onto a two dimensional image. Of course, advanced computed tomography (CT) algorithms exist since many years, but if the object to investigate is too large to fit into the manipulation system or its shape is not appropriate, CT is not feasible or sensible to be applied. To overcome this limitation, numerous laminographic algorithms have been developed in the past. In this study, photon counting detectors are used in combination with co-planar translational laminography to gain reconstructed three-dimensional volumes. Both laminographic testing and PCDs require a serious knowledge of many parameters that can influence the image quality in the resulting datasets. These are e.g. the detector efficiency and calibration procedure, setting of energy thresholds, exposure data, number of projections, beam length correction and spatial resolution. The use of PCDs yields more variables to be considered compared to CIDs. The most important parameters in laminographic testing and in the use of PCDs are described in this study and limits are discussed.
Achieving reliability in NDE for nuclear power plants is a complex challenge. As engineers we tend to focus on the equipment and the written procedures; they are easy for us to understand, measure and control. This focus addresses only one of the four aspects of the BAM holistic model, namely, Intrinsic Capability. Another of the model's modules, Application Parameters, also is engineering-oriented as examiners work to ensure that the equipment and procedure can be applied correctly in the actual examination environment as it is found in the field, though in addition to engineering it requires organizational foresight and commitment to understand and prepare for that specific environment well in advance. The Human Factors reliability module is harder for us to think about. The procedure developers think, "Of course all the examiners in the field will understand all aspects of my procedure and execute them correctly." Most of our bad experiences with reliability occur when this happy thought turns out to be untrue. And finally, perhaps the hardest reliability module to affect is Organizational Context. Getting all of the stakeholders -- the plant owner, the NDE company, the examiners, the regulators, the qualification body, the equipment suppliers -- to think about reliability in the same way, years in advance of the examination, to think about reliability at every step in the long process leading to the day of the examination itself, is a heavy lift indeed.
Recent progress in the development of A1GaN/GaN heterostructure field effect transistors (HFETs) Shows the great potential towards high temperature / high power electronics. Nevertheless investigations on reliability properties of GaN-based devices are still at the beginning. The frequently used Ti/A1 based ohmic and Pt based Schottky contacts suffer from strong Degradation after aging at elevated temperatures. Therefore new contact systems have to be employed. Concerning the source and drain metallization we used an amorphous WSiN barrier layer as applied for GaAs on top of the Ti/Al-based ohmic contact. This technique significantly reduces the in-diffusion of the Au-containing overlayer, furthermore the barrier layer guaranties smooth contact morphology after RTA and aging, respectively. For the Schottky metallization the Ir/Au system was used. Reliability studies performed on HFET devices containing refractory Ti/A1/Ti/Au/WSiN ohmic and Ir/Au Schottky contacts demonstrate stable conditions during 120h aging at 500°C.
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.