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

Yashar Javadi; Ehsan Mohseni; Charles N. MacLeod; David Lines; Momchil Vasilev; Carmelo Mineo; Euan Foster; Stephen G. Pierce; Anthony Gachagan

doi:10.1016/j.matdes.2020.108655

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

Yashar Javadi, Ehsan Mohseni, Charles N. MacLeod, David Lines, Momchil Vasilev, Carmelo Mineo, Euan Foster, Stephen G. Pierce, Anthony Gachagan

Research output: Contribution to journal › Article › peer-review

8 Citations (Scopus)

54 Downloads (Pure)

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 language	English
Article number	108655
Number of pages	12
Journal	Materials and Design
Volume	191
Early online date	19 Mar 2020
DOIs	https://doi.org/10.1016/j.matdes.2020.108655
Publication status	Published - 30 Jun 2020

Keywords

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

Access to Document

10.1016/j.matdes.2020.108655Licence: CC BY 4.0

Javadi-etal-MD-2020-Continuous-monitoring-of-an-intentionally-manufactured-crackFinal published version, 7.02 MBLicence: CC BY 4.0

Yashar Javadi
- yashar.javadistrath.acuk
- Electronic And Electrical Engineering - Lecturer B
Person: Academic

1 Active
3 Finished

New Wire Additive Manufacture- NEWAM
Pierce, G., Gachagan, A. & MacLeod, C. N.
EPSRC (Engineering and Physical Sciences Research Council)
25/06/18 → 24/06/23
Project: Research
Robotic Wire + Arc Additive Manufacture cell
Pierce, G., Gachagan, A., Ion, W. & MacLeod, C. N.
EPSRC (Engineering and Physical Sciences Research Council)
1/07/17 → 31/03/21
Project: Research
Autonomous Inspection in Manufacturing & Remanufacturing (AIMaReM)
Pierce, G., Dobie, G., Gachagan, A., Ijomah, W., Ion, W. & MacLeod, C. N.
EPSRC (Engineering and Physical Sciences Research Council)
1/05/16 → 31/12/20
Project: Research

Cite this

@article{3c68e89885e24d3bb56dc9186ed50634,

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

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.",

keywords = "crack growth monitoring, ultrasonic phased array, in-process inspection, robotic NDE, intentionally manufactured weld defects, robotic welding",

author = "Yashar Javadi and Ehsan Mohseni and MacLeod, {Charles N.} and David Lines and Momchil Vasilev and Carmelo Mineo and Euan Foster and Pierce, {Stephen G.} and Anthony Gachagan",

year = "2020",

month = jun,

day = "30",

doi = "10.1016/j.matdes.2020.108655",

language = "English",

volume = "191",

journal = "Materials & Design",

issn = "0261-3069",

}

Continuous monitoring of an intentionally-manufactured crack using an automated welding and in-process inspection system. / Javadi, Yashar ; Mohseni, Ehsan ; MacLeod, Charles N.; Lines, David ; Vasilev, Momchil; Mineo, Carmelo; Foster, Euan ; Pierce, Stephen G.; Gachagan, Anthony.

In: Materials and Design, Vol. 191, 108655, 30.06.2020.

Research output: Contribution to journal › Article › peer-review

TY - JOUR

T1 - Continuous monitoring of an intentionally-manufactured crack using an automated welding and in-process inspection system

AU - Javadi, Yashar

AU - Mohseni, Ehsan

AU - MacLeod, Charles N.

AU - Lines, David

AU - Vasilev, Momchil

AU - Mineo, Carmelo

AU - Foster, Euan

AU - Pierce, Stephen G.

AU - Gachagan, Anthony

PY - 2020/6/30

Y1 - 2020/6/30

N2 - 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.

AB - 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.

KW - crack growth monitoring

KW - ultrasonic phased array

KW - in-process inspection

KW - robotic NDE

KW - intentionally manufactured weld defects

KW - robotic welding

U2 - 10.1016/j.matdes.2020.108655

DO - 10.1016/j.matdes.2020.108655

M3 - Article

VL - 191

JO - Materials & Design

JF - Materials & Design

SN - 0261-3069

M1 - 108655

ER -

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

Abstract

Keywords

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Yashar Javadi

Projects

New Wire Additive Manufacture- NEWAM

Robotic Wire + Arc Additive Manufacture cell

Autonomous Inspection in Manufacturing & Remanufacturing (AIMaReM)

Cite this