Investigation of Infrared Thermography NDE Techniques for Use in Power Station Environments

Three active thermal methods capable of detecting surface breaking cracks in metals are considered in this Thesis. The three thermal methods exploit different means of excitation, each with practical advantages and varying abilities to detect specific types of crack morphology. Thermosonics uses a broadband, high power ultrasonic input to vibrate the test-piece. Defects damp the vibrational energy into heat which is imaged by a thermal camera. Laser-spot thermography uses a short laser pulse to spot heat the surface of the test-piece, and the subsequent radial heat diffusion is then observed. Defects can cause both increased emission of infrared and localised increases in thermal impedance, both effects causing distortion of the radial heat diffusion. Eddy-current induced thermography uses a high power magnetic field to induce a flow of current inside the test-piece. Defects create a localised increase in electrical impedance, diverting the electric field around the defect. This diversion of current flow causes neighbouring regions of high and low current density, the corresponding Joule heating imaged by a thermal camera. In this Thesis the three methods are explored experimentally. For laser-spot thermography and eddy-current induced thermography the physical phenomena are characterised and experimental best-practice for short pulse excitation determined. The effect of crack opening on each of the three methods is found to give insight into which applications the methods are most suited. It was found that the relationship between crack opening and detectability was complex for thermosonics, relatively linear for laser-spot thermography, and that eddy-current induced thermography is largely insensitive to crack opening. The methods are tested for the feasibility of detecting cracks in Inconel buried beneath metallic and ceramic coatings typical of gas turbine blades, with thermosonics and eddy-current induced thermography found to be viable methods. A study of the detectability of a large number of cracks in steel, titanium and Waspaloy by eddy-current induced thermography is detailed, and from this data the probability of detection is established. Eddy-current thermography is shown to be an extremely sensitive method capable of detecting fatigue cracks of approximately 0.25 mm in steel and 0.50-0.75 mm in titanium and Waspaloy. The practicality of the thermal methods is discussed, and the methods put into the context of the wider field of NDE. Based on the works in this Thesis it was found that for most applications eddy-current induced thermography is the most appealing thermal method since it is highly sensitive, rapid, non-contacting and relatively easy to validate. However, both thermosonics and laser-spot thermography remain useful alternative inspections for more niche applications

Comparative study of infrared thermography, ultrasonic C-scan, X-ray computed tomography and terahertz imaging on composite materials

L’évaluation non destructive (NDT) des matériaux composites est compliquée en raison de la vaste gamme de défauts rencontrés (y compris délaminage, microfissuration, fracture de la fibre, retrait des fibres, fissuration matricielle, inclusions, vides et dommages aux chocs). La capacité de caractériser quantitativement le type, la géométrie et l’orientation des défauts est essentielle. La thermographie infrarouge (IRT), en tant que technique de diagnostic d’image, peut satisfaire le besoin industriel croissant de NDT&E. Dans la thèse, la thermographie par excitation optique et mécanique a été utilisée pour étudier différents matériaux composites, dont 1) des préformes sèches en fibres de carbone, 2) des composites de fibres naturelles, 3) des composites hybrides de basalte-fibres de carbone soumis à une charge d’impact (séquence de type sandwich et séquence d’empilement intercalé), 4) des défauts micro-dimensionnés dans un composite polymère renforcé de fibre de carbone (CFRP) en 3D avec une couture de type « joint en T », et 5) des peintures sur toile qui peuvent être considérées comme des matériaux composites. Une nouvelle technique IRT de thermographie de ligne par micro-laser (micro-LLT) a été proposée pour l’évaluation des porosités submillimétriques dans le CFRP. La microscopie de points par micro-laser (micro-LST) et la micro-vibrothermographie (micro-VT) ont également été présentées avec l’utilisation de microlentilles. La thermographie pulsée (PT) et la thermographie modulée « à verrouillage » (LT) ont été comparées à la tomographie par rayons X (TC) pour validation. Le C-scan ultrasonore (UT) et l’imagerie par ondes tera-hertziennes en onde continue (CW THz) ont également été réalisés à des fins comparatives. L’inspection par techniques thermographiques est une question ouverte à discuter pour le public scientifique. En fait, la thermographie par impulsions (PPT) basée sur la transformation de phase a été utilisée pour estimer la profondeur des dommages. Pour traiter les données thermographiques, on a également utilisé la reconstruction de signal thermographique de base (B-TSR), la thermographie des composants principaux (PCT) et la thermographie des moindres carrés partiels (PLST). Enfin, une analyse complète et comparative basée sur le diagnostic d’images thermographiques a été menée en vue d’applications industrielles potentielles.Non-destructive testing (NDT) of composite materials is complicated due to the wide range off laws encountered (including delamination, micro-cracking, fiber fracture, fiber pullout, matrix cracking, inclusions, voids, and impact damage). The ability to quantitatively characterize the type, geometry, and orientation of flaws is essential. Infrared thermography (IRT), as an image diagnostic technique, can satisfy the increasing industrial need for NDT&E. In the thesis, optical and mechanical excitation thermography were used to investigate different composite materials, including 1) carbon fiber dry preforms, 2) natural fiber composites, 3) basalt-carbon fiber hybrid composites subjected to impact loading (sandwich-like and intercalated stacking sequence), 4) micro-sized flaws in a stitched T-joint 3D carbon fiber reinforced polymer composite (CFRP), and 5) paintings on canvas which can be considered as composite materials. Of particular interest, a new IRT technique micro-laser line thermography (micro-LLT) was proposed for the evaluation of submillimeter porosities in CFRP. Micro-laser spot thermography (micro-LST) and micro-vibrothermography (micro-VT) were also presented with the usage of a micro-lens. Pulsed thermography (PT) and lock-in thermography (LT) were compared with x-ray computed tomography (CT) for validation. Ultrasonic C-scan (UT) and continuous wave terahertz imaging (CW THz) were also conducted for the comparative purpose. The inspection by thermographic techniques is an open matter to be discussed for the scientific audience. In fact, pulse phase thermography (PPT) based on phase transform was used to estimate the damage depth. Basic thermographic signal reconstruction (B-TSR), principal component thermography (PCT) and partial least squares thermography (PLST) (another more recent advanced image processing technique) were also used to pro-cess the thermographic data. Finally, a comprehensive and comparative analysis based on thermographic image diagnostics was conducted in view of potential industrial applications

Detection and quantification of delamination in concrete via time-lapse thermography with machine learning

This study developed a framework to automatically extract sub-surface defects from time-lapse thermography (TLT) images of reinforced concrete bridge components. Traditional approaches for processing TLT data typically require manual interventions that are not easily scaled to a large network of concrete bridges. A backbone of robust algorithms for detecting and analyzing deep sub-surface defects in concrete is needed to support condition assessment of concrete structures such as bridges. The current study leverages advances in adaptive signal and image processing to develop a fully automated TLT data processing pipeline that is capable of efficiently detecting defects at different depths in concrete. The methodology decomposes raw TLT datasets into narrow band time-frequency domains via a multiscale data analysis approach called a Wavelet Transform. The resulting decomposed modes are mined to extract defect information using thermal contrast enhancement routines. An objective measure of effectiveness based on signal-to-noise ratio was developed and used to compare the current framework with traditional approaches for processing TLT data. Active contour models were also designed to automatically extract the boundary location and geometric properties of the sub-surface defects. The results of this study show that the detection of deeper defects (3 in. and beyond) can be improved by analyzing the time-frequency response of surface temperature variations over a period of time. Compared to traditional lock-in algorithms and conventional infrared thermography images, the proposed framework is more effective at removing noisy information and produces images with greater contrast between intact and defective areas of concrete. Furthermore, a new process has been established to predict depths of delamination in reinforced concrete bridge components. For previous works, traditional approaches were adopted to quantify depths in active thermography, which mainly depend on estimated models as a function of time, frequency, phase contrast, material properties of specimens. This work deals with the passive thermography that is affected by several environmental parameters such as solar heating, daytime or nighttime, wind speed, clouds, shadow. The current work has employed the Machine Learning (ML) technology to estimate defect depths in concrete block. Features, such as phases, amplitudes, frequencies, have been extracted by utilizing the Fast Fourier Transform (FFT) in a stage of analysis. Furthermore, additional subfeatures, minor features, have been added to the ML analysis, for instance average and/or subtraction values between the maxima and minima features, to attain an acceptable learning performance. Support vector machine (SVM) and k-Nearest Neighbor (KNN) classifiers have been trained by using crossvalidation with different folds and hold validations. The predicted models have achieved an improved accuracy in estimating delamination depths in the concrete specimens with a good agreement.Includes bibliographical references

Performance of frequency and/or phase modulated excitation waveforms for optical infrared thermography of CFRPs through thermal wave radar : a simulation study

Following the developments in pulse compression techniques for increased range resolution and higher signal to noise ratio of radio wave radar systems, the concept of thermal wave radar (TWR) was introduced for enhanced depth resolvability in optical infrared thermography. However, considering the highly dispersive and overly damped behavior of heat wave, it is essential to systematically address both the opportunities and the limitations of the approach. In this regard, this paper is dedicated to a detailed analysis of the performance of TWR in inspection of carbon fiber reinforced polymers (CFRPs) through frequency and/or phase modulation of the excitation waveform. In addition to analogue frequency modulated (sweep) and discrete phase modulated (Barker binary coded) waveforms, a new discrete frequency-phase modulated (FPM) excitation waveform is introduced. All waveforms are formulated based on a central frequency so that their performance can be fairly compared to each other and to lock-in thermography at the same frequency. Depth resolvability of the waveforms, in terms of phase and lag of TWR, is firstly analyzed by an analytical solution to the 1D heat wave problem, and further by 3D finite element analysis which takes into account the anisotropic heat diffusivity of CFRPs, the non-uniform heating induced by the optical source and the measurement noise. The spectrum of the defect-induced phase contrast is calculated and, in view of that, the critical influence of the chosen central frequency and the laminate’s thickness on the performance of TWR is discussed. Various central frequencies are examined and the outstanding performance of TWR at relatively high excitation frequencies is highlighted, particularly when approaching the so-called blind frequency of a defect

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

Review and comparison of shearography and active thermography for nondestructive evaluation

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Detection of subsurface anomalies in fiber-reinforced polymer (FRP) wrapped timber bridge components using infrared thermography

This thesis presents the results of an experimental study on the use of Infrared Thermography technique for detection of subsurface anomalies in fiber reinforced polymer (FRP) wrapped timber bridge components. An extensive literature review on the application of various nondestructive evaluation techniques to composite structures has also been presented.;Simulated subsurface delaminations were constructed in the laboratory in timber piles wrapped with FRP composite fabric. The delaminations varied in size, thickness, and severity. These delaminations were placed between the 1/8&inches; thick FRP wrap and timber surface. The thermal images from the delaminated specimens were compared with thermal images from undamaged specimens to study the effect of subsurface anomalies. In addition, several field tests were conducted using the infrared imaging system on three timber railroad bridges located in Moorefield, West Virginia that were reinforced with FRP composite fabric. The field test data was used to detect debonds at the composite-timber interface and study the effect of environmental parameters on infrared images.;This study shows that the infrared thermography technique can be used to effectively to detect subsurface delaminations in timber components wrapped with FRP composite fabric. The study also shows the effect of different parameters (environmental conditions, heat source, etc.) on the clarity of infrared images

A confidence map based damage assessment approach using pulsed thermographic inspection

In the context of non-destructive testing, quantification of uncertainty caused by various factors such as inspection technique, testing environment and the operator is important and challenge. This paper introduces a concept of contour-based confidence map and an application framework for pulsed thermography that offers enhanced flexibility and reliability of inspection. This approach has been successfully applied to detect three flat-bottom holes of diameter 32, 16 and 8 mm drilled onto a 5 mm thick aluminium plate with a high accuracy of damage detection (R > 0.97). Its suitability and effectiveness in assessing impact damage occurring in composites have also been demonstrated