Three-dimensional eddy current pulsed thermography and its applications

Abstract

Ph. D. Thesis.The measurement and quantification of defects is a challenge for Non-DestructiveTesting and Evaluation (NDT&E). Such challenges include the precise localisation and detection of surface and sub-surface defects, as well as the quantification of such defects. This work first reports a three-dimensional (3D) Eddy Current Pulsed Thermography (ECPT) system via integration with an RGB-D camera. Then, various quantitative measurements and analyses of defects are carried out based on the 3D ECPT system. The ECPT system at Newcastle University has been prooven to be an effective nondestructive testing (NDT) method in surface and sub-surface detection over the past few years. Based on the different numerical or analytical models, it has achieved precise defect detection on the rail tracks, wind turbines, carbon fibre reinforced plastic (CFRP) and so on. The ECPT system has the advantage of fast inspection and a large lift-off range. However, it involves a trade-off between detectable defect size and inspection area compared with other NDT methods. In addition, there are challenges of defect detection in a complex structure. Thus, the quantification of defects gives a higher requirement of the measurement the object geometry information. Furthermore, the analysis of thermal diffusion requires a precise 3D model. For this reason, a 3D ECPT system is proposed that adds each heat pixel with an exact X-Y-Z coordinate. In this work, first, the 3D ECPT system is built. A feature-based automatic calibration of the infrared camera and the RGB-D camera is proposed. Second, the software platform is built. A fast 3D visualization is completed with multi-threading technology and the Point Cloud Library. Lastly, various studies of defect localization, quantification and thermal tomography reconstruction are carried ou