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

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Abstract

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 h. The crack was initiated 22 min after the weld ended and it grew quickly within the next 1.5 h. The crack growth stopped approximately after 2 h and no considerable change in the reflection signal was detected for the next 18 h of monitoring.

Original languageEnglish
Article number108655
Number of pages12
JournalMaterials and Design
Volume191
Early online date19 Mar 2020
DOIs
Publication statusPublished - 30 Jun 2020

Keywords

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

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