Development of a Versatile Laser Ultrasonic System and Application to On-Line Measurement for Process Control of Wall Thickness and Eccentrictiy of Steel Seamless Mechanical Tubing

Abstract

Researchers at the Timken Company conceived a project to develop an on-line instrument for wall thickness measurement of steel seamless mechanical tubing based on laser ultrasonic technology. The instrument, which has been installed and tested at a piercing mill, provides data on tube eccentricity and concentricity. Such measurements permit fine-tuning of manufacturing processes to eliminate excess material in the tube wall and therefore provide a more precisely dimensioned product for their customers. The resulting process energy savings are substantial, as is lowered environmental burden. The expected savings are $85.8 million per year in seamless mechanical tube piercing alone. Applied across the industry, this measurement has a potential of reducing energy consumption by 6 x 10{sup 12} BTU per year, greenhouse gas emissions by 0.3 million metric tons carbon equivalent per year, and toxic waste by 0.255 million pounds per year. The principal technical contributors to the project were the Timken Company, Industrial Materials Institute (IMI, a contractor to Timken), and Oak Ridge National Laboratory (ORNL). Timken provided mill access as well as process and metallurgical understanding. Timken researchers had previously developed fundamental ultrasonic analysis methods on which this project is based. IMI developed and fabricated the laser ultrasonic generation and receiver systems. ORNL developed Bayesian and wavelet based real-time signal processing, spread-spectrum wireless communication, and explored feature extraction and pattern recognition methods. The resulting instrument has successfully measured production tubes at one of Timken's piercing mills. This report concentrates on ORNL's contribution through the CRADA mechanism. The three components of ORNL's contribution were met with mixed success. The real-time signal-processing task accomplished its goal of improvement in detecting time of flight information with a minimum of false data. The signal processing algorithm development resulted in a combination of processing steps that can be set to generate no spoofs from noise, while simultaneously missing fewer than 10% of good trials. The algorithm leads to a 95% probability that the estimate of time of flight is good to within 4 time bins or fewer for laser excitations above 30 mJ for the first two echoes of the signal. Receiver Operating Characteristic (ROC) curves for the algorithm indicate that the algorithm is very robust against errors for excitations above at 35 mJ and above, tolerable at 30 mJ and unacceptable below 30 mJ