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.
- crack growth monitoring
- ultrasonic phased array
- in-process inspection
- robotic NDE
- intentionally manufactured weld defects
- robotic welding
Javadi, Y., Mohseni, E., MacLeod, C. N., Lines, D., Vasilev, M., Mineo, C., ... Gachagan, A. (2020). Continuous monitoring of an intentionally-manufactured crack using an automated welding and in-process inspection system. Materials and Design, 191, . https://doi.org/10.1016/j.matdes.2020.108655