Three-dimensional scanning of specular and diffuse metallic surfaces using an infrared technique

For the past two decades, the need for three-dimensional (3-D) scanning of industrial objects has increased significantly and many experimental techniques and commercial solutions have been proposed. However, difficulties remain for the acquisition of optically non-cooperative surfaces, such as transparent or specular surfaces. To address highly reflective metallic surfaces, we propose the extension of a technique that was originally dedicated to glass objects. In contrast to conventional active triangulation techniques that measure the reflection of visible radiation, we measure the thermal emission of a surface, which is locally heated by a laser source. Considering the thermophysical properties of metals, we present a simulation model of heat exchanges that are induced by the process, helping to demonstrate its feasibility on specular metallic surfaces and predicting the settings of the system. With our experimental device, we have validated the theoretical modeling and computed some 3-D point clouds from specular surfaces of various geometries. Furthermore, a comparison of our results with those of a conventional system on specular and diffuse parts will highlight that the accuracy of the measurement no longer depends on the roughness of the surface

A review of miniaturised Non-Destructive Testing technologies for in-situ inspections

Non-destructive testing (NDT) techniques have become attractive trends of product manufacturing, installation and post-maintenance in the aerospace, automotive and manufacturing industry, because of its benefits such as cost saving, easy to use and high efficiency etc. With the industrial products becoming large-scale, high integration and complication, developing the NDT miniaturisation technique for in-situ inspections is highly demanded and becoming an inevitable trend. However, in-situ inspection using NDT have been limited by a number of factors, such as the heavy weight, large size or complex structure etc. This paper aims to systematically identify and analyse the current state-of-the-art of NDT miniaturisation techniques in research and innovation, and discuss the challenge and prospect of miniaturisation of the commonly used NDT techniques

Infrared Thermography for Weld Inspection: Feasibility and Application

Traditional ultrasonic testing (UT) techniques have been widely used to detect surface and sub-surface defects of welds. UT inspection is a contact method which burdens the manufacturer by storing hot specimens for inspection when the material is cool. Additionally, UT is only valid for 5 mm specimens or thicker and requires a highly skilled operator to perform the inspections and interpret the signals. Infrared thermography (IRT) has the potential to be implemented for weld inspections due to its non-contact nature. In this study, the feasibility of using IRT to overcome the limitations of UT inspection is investigated to detect inclusion, porosity, cracking, and lack of fusion in 38 weld specimens with thicknesses of 3, 8 and 13 mm. UT inspection was also performed to locate regions containing defects in the 8 mm and 13 mm specimens. Results showed that regions diagnosed with defects by the UT inspection lost heat faster than the sound weld. The IRT method was applied to six 3 mm specimens to detect their defects and successfully detected lack of fusion in one of them. All specimens were cut at the locations indicated by UT and IRT methods which proved the presence of a defect in 86% of the specimens. Despite the agreement with the UT inspection, the proposed IRT method had limited success in locating the defects in the 8 mm specimens. To fully implement in-line IRT-based weld inspections more investigations are required

Depth estimation of inner wall defects by means of infrared thermography

There two common methods dealing with interpreting data from infrared thermography: qualitatively and quantitatively. On a certain condition, the first method would be sufficient, but for an accurate interpretation, one should undergo the second one. This report proposes a method to estimate the defect depth quantitatively at an inner wall of petrochemical furnace wall. Finite element method (FEM) is used to model multilayer walls and to simulate temperature distribution due to the existence of the defect. Five informative parameters are proposed for depth estimation purpose. These parameters are the maximum temperature over the defect area (Tmax-def), the average temperature at the right edge of the defect (Tavg-right), the average temperature at the left edge of the defect (Tavg-left), the average temperature at the top edge of the defect (Tavg-top), and the average temperature over the sound area (Tavg-so). Artificial Neural Network (ANN) was trained with these parameters for estimating the defect depth. Two ANN architectures, Multi Layer Perceptron (MLP) and Radial Basis Function (RBF) network were trained for various defect depths. ANNs were used to estimate the controlled and testing data. The result shows that 100% accuracy of depth estimation was achieved for the controlled data. For the testing data, the accuracy was above 90% for the MLP network and above 80% for the RBF network. The results showed that the proposed informative parameters are useful for the estimation of defect depth and it is also clear that ANN can be used for quantitative interpretation of thermography data

A comparative study of image processing thresholding algorithms on residual oxide scale detection in stainless steel production lines

The present work is intended for residual oxide scale detection and classification through the application of image processing techniques. This is a defect that can remain in the surface of stainless steel coils after an incomplete pickling process in a production line. From a previous detailed study over reflectance of residual oxide defect, we present a comparative study of algorithms for image segmentation based on thresholding methods. In particular, two computational models based on multi-linear regression and neural networks will be proposed. A system based on conventional area camera with a special lighting was installed and fully integrated in an annealing and pickling line for model testing purposes. Finally, model approaches will be compared and evaluated their performance..Universidad de Málaga. Campus de Excelencia Internacional Andalucía Tech

NDE: An effective approach to improved reliability and safety. A technology survey

Technical abstracts are presented for about 100 significant documents relating to nondestructive testing of aircraft structures or related structural testing and the reliability of the more commonly used evaluation methods. Particular attention is directed toward acoustic emission; liquid penetrant; magnetic particle; ultrasonics; eddy current; and radiography. The introduction of the report includes an overview of the state-of-the-art represented in the documents that have been abstracted

An Infrared Camera for Leuschner Observatory and the Berkeley Undergraduate Astronomy Lab

We describe the design, fabrication, and operation of an infrared camera which is in use at the 30-inch telescope of the Leuschner Observatory. The camera is based on a Rockwell PICNIC 256 x 256 pixel HgCdTe array, which is sensitive from 0.9-2.5 micron. The primary purpose of this telescope is for undergraduate instruction. The cost of the camera has been minimized by using commercial parts whereever practical. The camera optics are based on a modified Offner relay which forms a cold pupil where stray thermal radiation from the telescope is baffled. A cold, six-position filter wheel is driven by a cryogenic stepper motor, thus avoiding any mechanical feed throughs. The array control and readout electronics are based on standard PC cards; the only custom component is a simple interface card which buffers the clocks and amplifies the analog signals from the array.Comment: 13 pages, 17 figures. Submitted to Publications of the Astronomical Society of the Pacific: 2001 Jan 10, Accepted 2001 Jan 1

A fundamental work on THz measurement techniques for application to steel manufacturing processes

The terahertz (THz) waves had not been obtained except by a huge system, such as a free electron laser, until an invention of a photo-mixing technique at Bell laboratory in 1984 [1]. The first method using the Auston switch could generate up to 1 THz [2]. After then, as a result of some efforts for extending the frequency limit, a combination of antennas for the generation and the detection reached several THz [3, 4]. This technique has developed, so far, with taking a form of filling up the so-called THz gap . At the same time, a lot of researches have been trying to increase the output power as well [5-7]. In the 1990s, a big advantage in the frequency band was brought by non-linear optical methods [8-11]. The technique led to drastically expand the frequency region and recently to realize a measurement up to 41 THz [12]. On the other hand, some efforts have yielded new generation and detection methods from other approaches, a CW-THz as well as the pulse generation [13-19]. Especially, a THz luminescence and a laser, originated in a research on the Bloch oscillator, are recently generated from a quantum cascade structure, even at an only low temperature of 60 K [20-22]. This research attracts a lot of attention, because it would be a breakthrough for the THz technique to become widespread into industrial area as well as research, in a point of low costs and easier operations. It is naturally thought that a technology of short pulse lasers has helped the THz field to be developed. As a background of an appearance of a stable Ti:sapphire laser and a high power chirped pulse amplification (CPA) laser, instead of a dye laser, a lot of concentration on the techniques of a pulse compression and amplification have been done. [23] Viewed from an application side, the THz technique has come into the limelight as a promising measurement method. A discovery of absorption peaks of a protein and a DNA in the THz region is promoting to put the technique into practice in the field of medicine and pharmaceutical science from several years ago [24-27]. It is also known that some absorption of light polar-molecules exist in the region, therefore, some ideas of gas and water content monitoring in the chemical and the food industries are proposed [28-32]. Furthermore, a lot of reports, such as measurements of carrier distribution in semiconductors, refractive index of a thin film and an object shape as radar, indicate that this technique would have a wide range of application [33-37]. I believe that it is worth challenging to apply it into the steel-making industry, due to its unique advantages. The THz wavelength of 30-300 ¼m can cope with both independence of a surface roughness of steel products and a detection with a sub-millimeter precision, for a remote surface inspection. There is also a possibility that it can measure thickness or dielectric constants of relatively high conductive materials, because of a high permeability against non-polar dielectric materials, short pulse detection and with a high signal-to-noise ratio of 103-5. Furthermore, there is a possibility that it could be applicable to a measurement at high temperature, for less influence by a thermal radiation, compared with the visible and infrared light. These ideas have motivated me to start this THz work

In-Situ Defect Detection in Laser Powder Bed Fusion by Using Thermography and Optical Tomography—Comparison to Computed Tomography

Among additive manufacturing (AM) technologies, the laser powder bed fusion (L-PBF) is one of the most important technologies to produce metallic components. The layer-wise build-up of components and the complex process conditions increase the probability of the occurrence of defects. However, due to the iterative nature of its manufacturing process and in contrast to conventional manufacturing technologies such as casting, L-PBF offers unique opportunities for in-situ monitoring. In this study, two cameras were successfully tested simultaneously as a machine manufacturer independent process monitoring setup: a high-frequency infrared camera and a camera for long time exposure, working in the visible and infrared spectrum and equipped with a near infrared filter. An AISI 316L stainless steel specimen with integrated artificial defects has been monitored during the build. The acquired camera data was compared to data obtained by computed tomography. A promising and easy to use examination method for data analysis was developed and correlations between measured signals and defects were identified. Moreover, sources of possible data misinterpretation were specified. Lastly, attempts for automatic data analysis by data integration are presented