Residual stress analysis in robotically welded plates using phased array ultrasonics with validation through neutron diffraction and hole-drilling methods

Brandon Mills; Joseph Walker; Yashar Javadi; Charles N. MacLeod; Houman Alipooramirabad; Mark  Reid; Anna  Paradowska

doi:10.1016/j.ijpvp.2025.105518

Residual stress analysis in robotically welded plates using phased array ultrasonics with validation through neutron diffraction and hole-drilling methods

Brandon Mills^*, Joseph Walker, Yashar Javadi, Charles N. MacLeod, Houman Alipooramirabad, Mark Reid, Anna Paradowska

^*Corresponding author for this work

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

Abstract

This paper explores Residual Stress (RS) measurement in two robotically welded, S275 plates using Phased Array Ultrasonics for Residual Stress Measurement (PAURS) and Neutron Diffraction (ND), with the Incremental Hole Drilling (IHD) method employed for validation. Pogo ultrasonic simulation was used to model the Longitudinal Critically Refracted (LCR) wave and design the ultrasonic setup. Ultrasonic arrays operating at 5 MHz (8 elements) measured RS at a depth of ∼1.25 mm. Results show qualitative agreement among PAURS, ND, and IHD, with RS symmetrically distributed on both sides of the plates, validating the effectiveness of phased array probes for qualitative measurement. However, discrepancies in precise numerical values were observed across methods. As PAURS is a novel technique for welded samples, the paper highlights areas for improvement to enhance its quantitative measurement capabilities.

Original language	English
Article number	105518
Number of pages	19
Journal	International Journal of Pressure Vessels and Piping
Volume	216
Early online date	28 Mar 2025
DOIs	https://doi.org/10.1016/j.ijpvp.2025.105518
Publication status	E-pub ahead of print - 28 Mar 2025

Funding

This work was a multi-disciplinary collaboration between various organisations, each supporting different aspects of the project. The robotic welding and sensor development were undertaken as part of the EPSRC-supported UK Research Centre in NDE (RCNDE – EP/L022125/1). Neutron Diffraction (ND) was supported by a beam-time project from ANSTO (N:P15462). Incremental Hole Drilling (IHD) was performed at StressCraft Ltd. The authors would like to acknowledge EPSRC, RCNDE, and ANSTO for their support and funding of the projects.

Keywords

RS measurement
phased array ultrasonic testing
robotic welding
ultrasonic simulation
neutron diffraction (ND)
incremental hole drilling (IHD)

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10.1016/j.ijpvp.2025.105518Licence: CC BY 4.0

Mills-etal-IJPVP-2025-Residual-stress-analysis-in-robotically-welded-platesFinal published version, 30.3 MBLicence: CC BY 4.0

Cite this

Mills, B., Walker, J., Javadi, Y., MacLeod, C. N., Alipooramirabad, H., Reid, M., & Paradowska, A. (2025). Residual stress analysis in robotically welded plates using phased array ultrasonics with validation through neutron diffraction and hole-drilling methods. International Journal of Pressure Vessels and Piping, 216, Article 105518. Advance online publication. https://doi.org/10.1016/j.ijpvp.2025.105518

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title = "Residual stress analysis in robotically welded plates using phased array ultrasonics with validation through neutron diffraction and hole-drilling methods",

abstract = "This paper explores Residual Stress (RS) measurement in two robotically welded, S275 plates using Phased Array Ultrasonics for Residual Stress Measurement (PAURS) and Neutron Diffraction (ND), with the Incremental Hole Drilling (IHD) method employed for validation. Pogo ultrasonic simulation was used to model the Longitudinal Critically Refracted (LCR) wave and design the ultrasonic setup. Ultrasonic arrays operating at 5 MHz (8 elements) measured RS at a depth of ∼1.25 mm. Results show qualitative agreement among PAURS, ND, and IHD, with RS symmetrically distributed on both sides of the plates, validating the effectiveness of phased array probes for qualitative measurement. However, discrepancies in precise numerical values were observed across methods. As PAURS is a novel technique for welded samples, the paper highlights areas for improvement to enhance its quantitative measurement capabilities.",

keywords = "RS measurement, phased array ultrasonic testing, robotic welding, ultrasonic simulation, neutron diffraction (ND), incremental hole drilling (IHD)",

author = "Brandon Mills and Joseph Walker and Yashar Javadi and MacLeod, {Charles N.} and Houman Alipooramirabad and Mark Reid and Anna Paradowska",

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AU - Javadi, Yashar

AU - MacLeod, Charles N.

AU - Alipooramirabad, Houman

AU - Reid, Mark

AU - Paradowska, Anna

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N2 - This paper explores Residual Stress (RS) measurement in two robotically welded, S275 plates using Phased Array Ultrasonics for Residual Stress Measurement (PAURS) and Neutron Diffraction (ND), with the Incremental Hole Drilling (IHD) method employed for validation. Pogo ultrasonic simulation was used to model the Longitudinal Critically Refracted (LCR) wave and design the ultrasonic setup. Ultrasonic arrays operating at 5 MHz (8 elements) measured RS at a depth of ∼1.25 mm. Results show qualitative agreement among PAURS, ND, and IHD, with RS symmetrically distributed on both sides of the plates, validating the effectiveness of phased array probes for qualitative measurement. However, discrepancies in precise numerical values were observed across methods. As PAURS is a novel technique for welded samples, the paper highlights areas for improvement to enhance its quantitative measurement capabilities.

AB - This paper explores Residual Stress (RS) measurement in two robotically welded, S275 plates using Phased Array Ultrasonics for Residual Stress Measurement (PAURS) and Neutron Diffraction (ND), with the Incremental Hole Drilling (IHD) method employed for validation. Pogo ultrasonic simulation was used to model the Longitudinal Critically Refracted (LCR) wave and design the ultrasonic setup. Ultrasonic arrays operating at 5 MHz (8 elements) measured RS at a depth of ∼1.25 mm. Results show qualitative agreement among PAURS, ND, and IHD, with RS symmetrically distributed on both sides of the plates, validating the effectiveness of phased array probes for qualitative measurement. However, discrepancies in precise numerical values were observed across methods. As PAURS is a novel technique for welded samples, the paper highlights areas for improvement to enhance its quantitative measurement capabilities.

KW - RS measurement

KW - phased array ultrasonic testing

KW - robotic welding

KW - ultrasonic simulation

KW - neutron diffraction (ND)

KW - incremental hole drilling (IHD)

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DO - 10.1016/j.ijpvp.2025.105518

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JF - International Journal of Pressure Vessels and Piping

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ER -

Residual stress analysis in robotically welded plates using phased array ultrasonics with validation through neutron diffraction and hole-drilling methods

Abstract

Funding

Keywords

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