Nondestructive Testing in Composite Materials

In this era of technological progress and given the need for welfare and safety, everything that is manufactured and maintained must comply with such needs. We would all like to live in a safe house that will not collapse on us. We would all like to walk on a safe road and never see a chasm open in front of us. We would all like to cross a bridge and reach the other side safely. We all would like to feel safe and secure when taking a plane, ship, train, or using any equipment. All this may be possible with the adoption of adequate manufacturing processes, with non-destructive inspection of final parts and monitoring during the in-service life of components. Above all, maintenance should be imperative. This requires effective non-destructive testing techniques and procedures. This Special Issue is a collection of some of the latest research in these areas, aiming to highlight new ideas and ways to deal with challenging issues worldwide. Different types of materials and structures are considered, different non-destructive testing techniques are employed with new approaches for data treatment proposed as well as numerical simulations. This can serve as food for thought for the community involved in the inspection of materials and structures as well as condition monitoring

Condition Monitoring Technologies for Steel Wire Ropes – A Review

In this research, we review condition-monitoring technologies for offshore steel wire ropes (SWR). Such ropes are used within several offshore applications including cranes for load handling such as subsea construction at depths up to 3-4000 meters, drilling lines, marine riser tensioner lines and anchor lines. For mooring, there is a clear tendency for using fiber ropes. Especially for heavy-lift cranes and subsea deployment, winches with strong ropes of up to 180 mm in diameter may be required, which has a considerable cost per rope, especially for large water depths. Today’s practice is to discard the rope after a predetermined number of uses due to fatigue from bending over sheaves with a large safety factor, especially for systems regulated by active heave compensation (AHC). Other sources of degradation are abrasion, fretting, corrosion and extreme forces, and are typically accelerated due to undersized or poorly maintained sheaves, groove type, lack of lubrication and excessive load. Non-destructive testing techniques for SWR have been developed over a period of 100 years. Most notably are the magnetic leakage techniques (electromagnetic methods), which are widely used within several industries such as mining and construction. The content reviewed in this research is primarily the developments the last five years within the topics of electromagnetic method, acoustic emissions (AE), ultrasound, X- and γ-rays, fiber optics, optical and thermal vision and current signature analysis. Each technique is thoroughly presented and discussed for the application of subsea construction. Assessments include ability to detect localized flaws (i.e. broken wire) both internally and externally, estimated loss of metallic cross sectional area, robustness with respect to the rough offshore environment, ability to evaluate both rope and end fittings, and ability to work during operation

Condition Monitoring Technologies for Synthetic Fiber Ropes - a Review

This paper presents a review of different condition monitoring technologies for fiber ropes. Specifically, it presents an overview of the articles and patents on the subject, ranging from the early 70’s up until today with the state of the art. Experimental results are also included and discussed in a conditionmonitoring context,where failuremechanisms and changes in physical parameters give improved insight into the degradation process of fiber ropes. From this review, it is found that automatic width measurement has received surprisingly little attention, and might be a future direction for the development of a continuous condition monitoring system for synthetic fiber ropes

Nondestructive Evaluation of Steel Bridges: Methods and Applications

Nondestructive evaluation (NDE) methods can be used to assess in-service steel bridges for problematic conditions caused by factors such as design, manufacturing, fabrication, and the service effects of traffic and corrosion. This report discusses typical NDE test methods used on bridges, including penetrant testing, magnetic particle testing, eddy current testing, ultrasonic testing (including phased array testing), radiography, and acoustic emission testing. NDE operations such as flaw location, characterization, and sizing are covered as well. Results of a national survey of departments of transportation’s (DOTs) use of NDE are presented. A simple procedure for using NDE to address DOT bridge concerns is proposed along with a risk-based inspection approach to scheduling/scoping bridge inspections

Non-Destructive Evaluation of Stay Cable Bridge Systems

Stay cable bridge systems have been used for centuries and as engineering knowledge and new materials has developed, these bridges have become larger, more elegant, and overall greater engineering feats. As these bridges become more popular, it is not only important to carefully design these bridges, but also to routinely inspect the health of the in-service bridges. Detrimental conditions such as corrosion, section loss, strand breakage, segregated grout, voided grout, water infiltration, and general tendon deterioration in the anchorage system are documented issues that can occur within stay cable bridges and can have extremely harmful effects. In order to monitor the health of these bridges, non-destructive evaluation (NDE) can be a very useful tool in order to inspect these bridges without having to repair the system after inspection. In this research, ground penetrating radar, magnetic flux leakage, infrared thermography, ultrasonic tomography, sounding, and borescope inspections are all performed on a series of mock-up stay cable specimens fabricated with certain detrimental conditions located within. The applicability, capabilities, and limitations of each NDE method are evaluated based on empirical data from physical testing. Furthermore, each method is ranked in categories of precision, accuracy, ease of use, inspection requirements, and cost. This research concludes that only magnetic flux leakage has the ability to determine any sort of steel strand defects, including corrosion, section loss, and strand breakage; and it was very effective in doing so, as testing data closely matched fabricated defects. Ground penetrating radar, infrared thermography, ultrasonic tomography, and sounding were all able to accurately identify grout voids within the tendon but could not differentiate between a voided region and a region infiltrated with water or poor grout conditions. In future research, additional testing to differentiate testing results between these three conditions should be explored, as each one can require completely different solutions to remedy the problem. In addition, none of the methods explored in this research were able to detect any defects within the concrete masses representative of the anchorage regions, although infrared thermography and sounding were effective at determining voided areas within the grout caps. Lastly, borescope inspection was a very useful tool to qualitatively evaluate conditions that have already been identified by one of the other methods

Development of Non-Destructive Testing by Eddy Currents for Highly Demanding Engineering Applications

Defect detection with Non-Destructive Testing (NDT) is essential in accidents prevention, requiring R&TD to generate new scientific and procedural knowledge for new products with high safety requirements. A current challenge lies in the detection of surface and sub-surface micro defects with NDT by Eddy Currents (EC). The main objective of this work was the development of applied research, technological innovation and experimental validation of EC customized systems for three highly demanding inspection scenarios: micro defects in tubular geometries; brazed joints for the automotive industry; and high-speed moving composite materials. This objective implied starting from the scientific fundamentals of NDT by EC to design and simulate EC probes and the prototypes developed were tested in industrial environment, reaching a TRL ≈ 5. Another objective, of a more scientific and disruptive nature, was to test a new technique for the creation of EC in the materials to be inspect, named Magnetic Permeability Pattern Substrate (MPPS). This technique consists on the development of substrates/films with patterns of different magnetic permeabilities rather than the use of excitation bobbin coils or filaments of complex geometry. The experimental results demonstrated that the prototypes developed for the three industrial applications studied outperformed the state of the art, allowing the detection of target defects with a very good signal-to-noise ratio: in tubular geometries defects with depth of 0.5 mm and thickness of 0.2 mm in any scanning position; in the laser brazed weld beads pores with 0.13 mm diameter and internal artificial defects 1 mm from the weld surface; in composite materials defects under 1 mm at speeds up to 4 m/s and 3 mm lift-off. The numerical simulations assisted the probe design, allowing to describe and characterize electrical and magnetic phenomena. The new MPPS concept for the introduction of EC was validated numerically and experimentally

A state-of-the-art review of non-destructive testing image fusion and critical insights on the inspection of aerospace composites towards sustainable maintenance repair operations

Non-destructive testing (NDT) of aerospace structures has gained significant interest, given its non-destructive and economic inspection nature enabling future sustainable aerospace maintenance repair operations (MROs). NDT has been applied to many different domains, and there is a number of such methods having their individual sensor technology characteristics, working principles, pros and cons. Increasingly, NDT approaches have been investigated alongside the use of data fusion with the aim of combining sensing information for improved inspection performance and more informative structural health condition outcomes for the relevant structure. Within this context, image fusion has been a particular focus. This review paper aims to provide a comprehensive survey of the recent progress and development trends in NDT-based image fusion. A particular aspect included in this work is providing critical insights on the reliable inspection of aerospace composites, given the weight-saving potential and superior mechanical properties of composites for use in aerospace structures and support for airworthiness. As the integration of NDT approaches for composite materials is rather limited in the current literature, some examples from non-composite materials are also presented as a means of providing insights into the fusion potential