Classification of induced magnetic field signals for the microstructural characterization of sigma phase in duplex stainless steels

Duplex stainless steels present excellent mechanical and corrosion resistance properties.However, when heat treated at temperatures above 600 ºC, the undesirable tertiary sigma phaseis formed. This phase presents high hardness, around 900 HV, and it is rich in chromium, thematerial toughness being compromised when the amount of this phase is not less than 4%. Thiswork aimed to develop a solution for the detection of this phase in duplex stainless steels throughthe computational classification of induced magnetic field signals. The proposed solution is based onan Optimum Path Forest classifier, which was revealed to be more robust and effective than Bayes,Artificial Neural Network and Support Vector Machine based classifiers. The induced magneticfield was produced by the interaction between an applied external field and the microstructure.Samples of the 2205 duplex stainless steel were thermal aged in order to obtain different amounts ofsigma phases (up to 18% in content). The obtained classification results were compared against theones obtained by Charpy impact energy test, amount of sigma phase, and analysis of the fracturesurface by scanning electron microscopy and X-ray diffraction. The proposed solution achieved aclassification accuracy superior to 95% and was revealed to be robust to signal noise, being thereforea valid testing tool to be used in this domain

Signal Processing for NDE

Nowadays, testing and evaluating of industrial equipment using nondestructive tests, is a fundamental step in the manufacturing process. The complexity and high costs of manufacturing industrial components, require examinations in some way about the quality and reliability of the specimens. However, it should be noted, that in order to accurately perform the nondestructive test, in addition to theoretical knowledge, it is also essential to have the experience and carefulness, which requires special courses and experience with theoretical education. Therefore, in the traditional methods, which are based on manual testing techniques and the test results depend on the operator, there is the possibility of an invalid inference from the test data. In other words, the accuracy of conclusion from the obtained data is dependent on the skill and experience of the operator. Thus, using the signal processing techniques for nondestructive evaluation (NDE), it is possible to optimize the methods of nondestructive inspection, and in other words, to improve the overall system performance, in terms of reliability and system implementation costs. In recent years, intelligent signal processing techniques have had a significant impact on the progress of nondestructive assessment. In other words, by automating the processing of nondestructive data and signals, and using the artificial intelligence methods, it is possible to optimize nondestructive inspection methods. Hence, improve overall system performance in terms of reliability and Implementation costs of the system. This chapter reviews the issues of intelligent processing of nondestructive testing (NDT) signals

Inteligência Artificial em Radiologia: Do Processamento de Imagem ao Diagnóstico

The objective of this article is to present a view on the potential impact of Artificial Intelligence (AI) on processing medical images, in particular in relation to diagnostic. This topic is currently attracting major attention in both the medical and engineering communities, as demonstrated by the number of recent tutorials [1-3] and review articles [4-6] that address it, with large research hospitals, as well as engineering research centers contributing to the area. Furthermore, several large companies like General Electric (GE), IBM/Merge, Siemens, Philips or Agfa, as well as more specialized companies and startups are integrating AI into their medical imaging products. The evolution of GE in this respect is interesting. GE SmartSignal software was developed for industrial applications to identify impending equipment failures well before they happen. As written in the GE prospectus, with this added lead time, one can transform from reactive maintenance to a more proactive maintenance process, allowing the workforce to focus on fixing problems rather than looking for them. With this background experience from the industrial field, GE developed predictive analytics products for clinical imaging, that embodied the Predictive component of P4 medicine (predictive, personalized, preventive, participatory). Another interesting example is the Illumeo software from Philips that embeds adaptive intelligence, i. e. the capacity to improve its automatic reasoning process from its past experience, to automatically pop out related prior exams for radiology in face of a concrete situation. Actually, with its capacity to tackle massive amounts of data of different sorts (imaging data, patient exam reports, pathology reports, patient monitoring signals, data from implantable electrophysiology devices, and data from many other sources) AI is certainly able to yield a decisive contribution to all the components of P4 medicine. For instance, in the presence of a rare disease, AI methods have the capacity to review huge amounts of prior information when confronted to the patient clinical data

Synthetic Data-Enhanced Deep Learning For Quality Control Of Automated Welding Processes

Automotive production systems are designed to produce large quantities in high quality and short throughput times and are therefore organized as line production. This places high quality requirements on the joining processes in automotive body shops, in which automated, robot-guided welding is a key process. The quality of these thermal joining processes depends on various physical and chemical influencing factors, whose interactions cannot be explicitly modelled. This leads to enormous quality assurance efforts in several quality control loops, which may include visual inspections, non-destructive testing of samples to assess the internal structure and destructive testing of samples for the assessment of mechanical properties such as tensile strength. Due to the increasing availability of data in automated processes and the complexity of welding processes, the application of Deep Learning has a great potential to reduce quality control efforts in automotive body shops. Using Deep Learning to leverage process data and accurately predict quality parameters in welding processes is investigated in research, yet model training requires a large, balanced and annotated dataset, whose generation is time and cost intensive, particularly for production data. However, there are generative AI methods such as Generative Adversarial Networks (GANs) that are able to generate synthetic data and thus offer the potential to generate a large amount of annotated production data with relatively little effort. This paper presents a systematic approach to evaluate the potential of incorporating synthetic data in a real-world production dataset to improve quality control using Deep Learning. The approach is validated for the analysis of real-world ultrasound images of resistance spot welding (RSW) processes from the automotive industry. Different Deep Learning architectures to generate synthetic data are compared. Results show that adding synthetic data to the training dataset can improve the accuracy of Deep Learning models for quality monitoring in welding processes

Induced magnetic field used to detect the sigma phase of a 2205 duplex stainless steel

Sigma phases are formed due to heat treatments and/or welding processes during the solidification stage, and they are responsible for embrittlement of duplex stainless steels. Only a small amount of this phase promotes unfavorable mechanical properties and liability to corrosion. In this work, a new affordable approach to detect and follow-up the kinetics of the sigma phase transformation is evaluated. The measurements are based on an induced magnetic field generated through the interaction between an external magnetic field and themicrostructure under study. To validate this approach, the induced magnetic field values are compared with the values of the Charpy impact energy, and the sigma phase is assessed by optical microscopy. Moreover, surface fractures are analyzed by scanning electron microscopy and X-ray diffraction. The results from the 2205 duplex stainless steel used showthat there is a direct relation among the impact energy, fracture mechanism and induced magnetic field. The method proved to be able to follow up the embrittlement of the DSS successfully. Moreover, the results confirm that the presence of a sigma phase can be studied based on an induced magnetic field, even when in low amounts, and that a critical threshold value can be defined to monitor structures in service

Automated Segmentation of Large Image Datasets using Artificial Intelligence for Microstructure Characterisation, Damage Analysis and High-Throughput Modelling Input

Many properties of commonly used materials are driven by their microstructure, which can be influenced by the composition and manufacturing processes. To optimise future materials, understanding the microstructure is critically important. Here, we present two novel approaches based on artificial intelligence that allow the segmentation of the phases of a microstructure for which simple numerical approaches, such as thresholding, are not applicable: One is based on the nnU-Net neural network, and the other on generative adversarial networks (GAN). Using large panoramic scanning electron microscopy images of dual-phase steels as a case study, we demonstrate how both methods effectively segment intricate microstructural details, including martensite, ferrite, and damage sites, for subsequent analysis. Either method shows substantial generalizability across a range of image sizes and conditions, including heat-treated microstructures with different phase configurations. The nnU-Net excels in mapping large image areas. Conversely, the GAN-based method performs reliably on smaller images, providing greater step-by-step control and flexibility over the segmentation process. This study highlights the benefits of segmented microstructural data for various purposes, such as calculating phase fractions, modelling material behaviour through finite element simulation, and conducting geometrical analyses of damage sites and the local properties of their surrounding microstructure.Comment: 37 pages, 24 figure

Automated recognition of lung diseases in CT images based on the optimum-path forest classifier

The World Health Organization estimated that around 300 million people have asthma, and 210 million people are affected by Chronic Obstructive Pulmonary Disease (COPD). Also, it is estimated that the number of deaths from COPD increased 30% in 2015 and COPD will become the third major cause of death worldwide by 2030. These statistics about lung diseases get worse when one considers fibrosis, calcifications and other diseases. For the public health system, the early and accurate diagnosis of any pulmonary disease is mandatory for effective treatments and prevention of further deaths. In this sense, this work consists in using information from lung images to identify and classify lung diseases. Two steps are required to achieve these goals: automatically extraction of representative image features of the lungs and recognition of the possible disease using a computational classifier. As to the first step, this work proposes an approach that combines Spatial Interdependence Matrix (SIM) and Visual Information Fidelity (VIF). Concerning the second step, we propose to employ a Gaussian-based distance to be used together with the optimum-path forest (OPF) classifier to classify the lungs under study as normal or with fibrosis, or even affected by COPD. Moreover, to confirm the robustness of OPF in this classification problem, we also considered Support Vector Machines and a Multilayer Perceptron Neural Network for comparison purposes. Overall, the results confirmed the good performance of the OPF configured with the Gaussian distance when applied to SIM- and VIF-based features. The performance scores achieved by the OPF classifier were as follows: average accuracy of 98.2%, total processing time of 117 microseconds in a common personal laptop, and F-score of 95.2% for the three classification classes. These results showed that OPF is a very competitive classifier, and suitable to be used for lung disease classification

Nondestructive evaluation and in-situ monitoring for metal additive manufacturing

Powder-based additive manufacturing (AM) technologies are seeing increased use, particularly because they give greatly enhanced design flexibility and can be used to form components that cannot be formed using subtractive manufacturing. There are fundamental differences in the morphology of additively manufactured materials, when compared with, for example castings or forgings. In all cases it is necessary to ensure that parts meet required quality standards and that “allowable” anomalies can be detected and characterized. It is necessary to understanding the various types of manufacturing defects and their potential effects on the quality and performance of AM, and this is a topic of much study. In addition, it is necessary to investigate quality from powder throughout the manufacturing process from powder to the finished part. In doing so it is essential to have metrology tools for mechanical property evaluation and for appropriate anomaly detection, quality control, and monitoring. Knowledge of how and when the various types of defects appear will increase the potential for early detection of significant flaws in additively manufactured parts and offers the potential opportunity for in-process intervention and to hence decrease the time and cost of repair or rework. Because the AM process involves incremental deposition of material, it gives unique opportunities to investigate the material quality as it is deposited. Due to the AM processes sensitivity to different factors such as laser power and material properties, any changes in aspects of the process can potentially have an impact on the part quality. As a result, in-process monitoring of additive manufacturing (AM) is crucial to assure the quality, integrity, and safety of AM parts. To meet this need there are a variety of sensing methods and signals which can be measured. Among the available measurement modalities, acoustic-based methods have the advantage of potentially providing real-time, continuous in-service monitoring of manufacturing processes at relatively low cost. In this research, the various types of microstructural features or defects, their generation mechanisms, their effect on bulk properties and the capabilities of existing characterization methodologies for powder-based AM parts are discussed and methods for in-situ non-destructive evaluation are reviewed. A proof-of-concept demonstration for acoustic measurements used for monitoring both machine and material state is demonstrated. The analyses have been performed on temporal and spectral features extracted from the acoustic signals. These features are commonly related to defect formation, and acoustic noise that is generated and can potentially characterize the process. A novel application of signal processing tools is used for identification of temporal and spectral features in the acoustic signals. A new approach for a K-means statistical classification algorithm is used for classification of different process conditions, and quantitative evaluation of the classification performance in terms of cohesion and isolation of the clusters. The identified acoustic signatures demonstrate potential for in-situ monitoring and quality control of the additive manufacturing process and parts. A numerical model of the temperature field and the ultrasonic wave displacement field induced by an incident pulsed laser on additively manufactured stainless steel 17 4 PH is established which is based on thermoelastic theory. The numerical results indicate that the thermoelastic source and the ultrasonic wave features are strongly affected by the characteristics of the laser source and the thermal and mechanical properties of the material. The magnitude and temporal-spatial distributions of the pulsed laser source energy are very important factors which determine not only the wave generation mechanisms, but also the amplitude and characteristics of the resulting elastic wave signals