Deep learning in automated ultrasonic NDE -- developments, axioms and opportunities

The analysis of ultrasonic NDE data has traditionally been addressed by a trained operator manually interpreting data with the support of rudimentary automation tools. Recently, many demonstrations of deep learning (DL) techniques that address individual NDE tasks (data pre-processing, defect detection, defect characterisation, and property measurement) have started to emerge in the research community. These methods have the potential to offer high flexibility, efficiency, and accuracy subject to the availability of sufficient training data. Moreover, they enable the automation of complex processes that span one or more NDE steps (e.g. detection, characterisation, and sizing). There is, however, a lack of consensus on the direction and requirements that these new methods should follow. These elements are critical to help achieve automation of ultrasonic NDE driven by artificial intelligence such that the research community, industry, and regulatory bodies embrace it. This paper reviews the state-of-the-art of autonomous ultrasonic NDE enabled by DL methodologies. The review is organised by the NDE tasks that are addressed by means of DL approaches. Key remaining challenges for each task are noted. Basic axiomatic principles for DL methods in NDE are identified based on the literature review, relevant international regulations, and current industrial needs. By placing DL methods in the context of general NDE automation levels, this paper aims to provide a roadmap for future research and development in the area.Comment: Accepted version to be published in NDT & E Internationa

Potential and limitations of NARX for defect detection in guided wave signals

Previously, a nonlinear autoregressive network with exogenous input (NARX) demonstrated an excellent performance, far outperforming an established method in optimal baseline subtraction, for defect detection in guided wave signals. The principle is to train a NARX network on defect-free guided wave signals to obtain a filter that predicts the next point from the previous points in the signal. The trained network is then applied to new measurement and the output subtracted from the measurement to reveal the presence of defect responses. However, as shown in this paper, the performance of the previous NARX implementation lacks robustness; it is highly dependent on the initialisation of the network and detection performance sometimes improves and then worsens over the course of training. It is shown that this is due to the previous NARX implementation only making predictions one point ahead. Subsequently, it is shown that multi-step prediction using a newly proposed NARX structure creates a more robust training procedure, by enhancing the correlation between the training loss metric and the defect detection performance. The physical significance of the network structure is explored, allowing a simple hyperparameter tuning strategy to be used for determining the optimal structure. The overall detection performance of NARX is also improved by multi-step prediction, and this is demonstrated on defect responses at different times as well as on data from different sensor pairs, revealing the generalisability of this method

Understanding System Complexity in the Non-Destructive Testing of Advanced Composite Products

Non-destructive testing (NDT) is a quality control measure designed to ensure the safety of products according to established variability thresholds. With the development of advanced technologies and a lack of formalised knowledge of the state-of-the-art, the National Composites Centre, Bristol, has identified that the increasing complexity of composite products will lead to some severe inspection challenges. To address the apparent knowledge gap and understand system complexity, a formulaic approach to introduce intelligence and improve the robustness of NDT operations is presented. The systemic development of a high-fidelity knowledge base (KB) involves the establishment of a capability matrix that maps material, component, and defect configuration to the capabilities and limitations of selected detection methods. Population and validation are demonstrated through the experimental testing of reference standards and evaluated against an assessment criteria. System complexity in ultrasonic testing operations focusses on capturing the inherent risks in inspection and the designation of evidence-based path plans for automation platforms. Anticipated deployment of the validated applicability data within the KB will allow for road-mapping of the inspection technique development and will provide opportunities for knowledge-based decision making. Moreover, the KB highlights the need for Design for Inspection, providing measurable data that the methodology should not be ignored

Strategies for guided acoustic wave inspection using mobile robots

Continuous non-destructive monitoring of large-scale structures is extremely challenging with traditional manual inspections. In this paper, we explore possible strategies that a collection of inspection robots could adopt to address this challenge. We envision the continuous inspection of a plate performed by multiple robots or a single robot that combines measurements from multiple locations. The robots use guided ultrasonic waves to interrogate a localized region for defects such as cracking or corrosion. In the detection stage, the receiver operating characteristic defines a detection zone in which a defect is thought to be present. In the localization stage, further measurements are made to locate the defect within this zone to a certain accuracy. We then address the question of what additional measurements are needed to achieve a given level of performance in the presence of uncertainty in robot locations? We explore this problem with Monte Carlo simulations that reveal the compromise between number of robots and performance in terms of defect location accuracy. In an experimental validation example on an aluminium plate, we show that six measurements arranged in a pentagon with a central measurement point leads to localization errors of similar magnitude to the uncertainty in sensor location