Continuous monitoring of an intentionally-manufactured crack using an automated welding and in-process inspection system

Research output: Contribution to journalArticle

1 Downloads (Pure)


Automated weld deposition coupled with the real-time robotic Non-Destructive Evaluation (NDE) is used in this paper. For performance verification of the in-process inspection system, an ‏intentionally ‎embedded defect, a tungsten rod, is introduced into the ‎multi-pass weld. A partially-filled groove (staircase) sample is also manufactured and ultrasonically tested to calibrate the real-time inspection implemented on all seven layers of the weld which are deposited progressively. The tungsten ‎rod is successfully detected in the real-time NDE of the deposited ‎position. The same robotic inspection system was then used to continuously monitor an intentionally-manufactured crack for 20 hours. The crack was initiated 22 minutes after the weld ended and it grew quickly within the next 1.5 hour. The crack growth stopped approximately after 2 hours and no considerable change in the reflection signal was detected for the next 18 hours of monitoring.
Original languageEnglish
Article number108655
Number of pages12
JournalMaterials and Design
Early online date19 Mar 2020
Publication statusE-pub ahead of print - 19 Mar 2020



  • crack growth monitoring
  • ultrasonic phased array
  • in-process inspection
  • robotic NDE
  • intentionally manufactured weld defects
  • robotic welding

Cite this