Showing papers by "Prabhu Rajagopal published in 2015"

Interaction of shear horizontal bend (SHB) guided mode with defects

Abstract: The authors have recently reported on the attractive properties of shear-horizontal type feature guided (SHB) waves for the inspection of 90° plate bends. Further to this, here the interaction of the SHB mode with transverse and longitudinal defects in the bend region is studied using 3D finite element simulations validated by experiments. Trends are discussed in light of the underlying wave mechanics principles. The results show that the SHB mode yields improved through-thickness defect resolution capabilities as compared to regular plate guided SH waves in view of mode confinement and higher frequencies used.

A study of internal structure in components made by additive manufacturing process using 3 D X-ray tomography

Abstract: Additive manufacturing methods are gaining increasing popularity for rapidly and efficiently manufacturing parts and components in the industrial context, as well as for domestic applications. However, except when used for prototyping or rapid visualization of components, industries are concerned with the load carrying capacity and strength achievable by additive manufactured parts. In this paper, the wire-arc additive manufacturing (AM) process based on gas tungsten arc welding (GTAW) has been examined for the internal structure and constitution of components generated by the process. High-resolution 3D X-ray tomography is used to gain cut-views through wedge-shaped parts created using this GTAW additive manufacturing process with titanium alloy materials. In this work, two different control conditions for the GTAW process are considered. The studies reveal clusters of porosities, located in periodic spatial intervals along the sample cross-section. Such internal defects can have a detrimental effect on the strength of the resulting AM components, as shown in destructive testing studies. Closer examination of this phenomenon shows that defect clusters are preferentially located at GTAW traversal path intervals. These results highlight the strong need for enhanced control of process parameters in ensuring components with minimal defects and higher strength.

Ultrasonic guided waves in elliptical annular cylinders

Abstract: This paper studies the influence of cross-section ovalness or ellipticity on lower order axisymmetric guided wave modes in thin pipes. The second longitudinal mode L(0,2) and the fundamental torsional mode T(0,1) are studied, as these are of interest to current pipe inspection. The semi-analytical finite element (FE) method is mainly used, with three-dimensional FE simulations for visualization and cross-validation of results. The studies reveal that even a small degree of ovalness can affect mode shapes and velocities. The effect is more pronounced on the L(0,2) mode than on T(0,1) and this may be important for practical inspection applications.

Low frequency axisymmetric longitudinal guided waves in eccentric annular cylinders.

Abstract: This paper studies the effect of axially uniform eccentricity on the modal structures and velocities of the lower order axisymmetric guided wave mode L(0,2) in circular tubes or pipes. The semi-analytical finite element method is mainly used, supported by fully three-dimensional finite element models and validated using experiments. The studies show that even a small eccentricity in the pipe can cause a loss in the L(0,2) mode axisymmetry, leading to its confinement in the thinned side of the pipe cross-section and also a reduction in mode velocities. The physics of this phenomenon is related to the feature-guiding and mode confinement effects noted in recent years in the literature, particularly studies on waveguides with local cross-section variations and curvature.

Online monitoring of cold metal transfer (CMT) process using infrared thermography

Abstract: Online (passive) thermographic inspection of overlap joints of aluminium and zinc coated steel sheets made by cold metal transfer weld brazing process was explored Different experimental trials were conducted for demonstrating the feasibility of thermographic inspection to detect the porosities, improper weld bead and to differentiate the pre weld temperature The whole process was monitored using infrared cameras in different wavelength region Image analysis algorithms were developed to reconstruct the thermal images that contain the signatures of the weld defects and to extract the pre weld temperature and its evolution with distance from the centre of the weld torch Post-weld radiography lends strong support to the observations

Feature-guided waves (FGW) in plate structures with 90° transverse bends

Abstract: Ultrasonic guided waves are attractive for rapid remote screening of large structures and today they are widely used in several practical applications including the inspection of pipe and plate installations. More recently, guided wave modal solutions confined in extended local features have attracted much research interest, offering the possibility of inspecting complex geometric or topographical features. Such feature-guided wave (FGW) modes have been reported in plate waveguides with local cross-section variation or curvature, and in annular circular cylinders with cross-sectional anomalies. This paper focuses on FGW phenomena in 90 degree structural bends in plate structures, which commonly occur in various industrial structures. Modal studies are carried out using the Semi-Analytical Finite Element (SAFE) method, while 3D finite element (FE) simulations are used to gain visualization of results and also obtain cross-validation. Our studies reveal, perhaps for the first time, the possibility of bend-guided modes of the shear-horizontal (SH) family, in addition those of the Rayleigh-Lamb family reported earlier in the literature. This mode has attractive properties including low attenuation and limited dispersion. We investigate effects of plate thickness and bend radius on the physics of FGW in bends, arguing the strong role of geometry and curvature effects in causing mode confinement. Preliminary experiments have also been carried out to validate the existence of such bend-guided mode.

An approach for defect visualization and identification in composite plate structures using air-coupled guided ultrasound

Abstract: Composite materials are today widely used in engineering applications because of superior strength-weight ratios offered by them as well as high structural performance and corrosion resistance. However defects such as fibre breakage, matrix cracking, de-bonding and delaminations in composites impact their structural integrity and reliability negatively and NDE techniques to rapidly identify such defects are valuable. Ultrasonic guided waves have over the years emerged as attractive tools for scanning of large structures and recently they have been considered for rapid inspection of plate and pipe installations. Air-coupled ultrasound for generation of Lamb waves is particularly attractive for composite applications in view of the non-contact inspection offered, as well as the possibilities for rapid mechanized scanning. In this paper we present damage identification and visualisation approaches for quasi-isotropic composite plate structures, based on air-coupled plate guided ultrasonic (Lamb) waves. In the implementation demonstrated, an 8-layered quasi-isotropic [0/+45/−45/90]s glass fibre reinforced plastics (GFRP) composite plate is interrogated using air-coupled pitch-catch guided ultrasound. Propagation of Lamb waves in the laminates and their interaction with delaminations of different sizes at various locations along the structure are studied using 3D finite element (FE) analysis. The visualization approach is validated using experiments, leading to quantitative predictions of defect parameters such as sizing, location and depth. The approach is also extended for the inspection of complex composite structural features such as I- and T-sections.

Novel method of defect identification in bent structures through feature-guided wave detection using fiber Bragg grating sensors

Abstract: Feature-guided waves (FGW) have emerged as a promising technique for structural health monitoring as they are well confined in local features such as bends and welds. In this paper, we propose and demonstrate a novel method for identifying defects in 90 transverse bent structures through FGW detection using fiber Bragg gratings. Our experimental results are in excellent agreement with results predicted using 3D-Finite Element (FE) simulations of the bent structure.

Ultrasonic guided waves in bone system with degradation

Abstract: This paper investigates the feasibility of using ultrasonic guided waves for assessing the cortical bone and hence detect conditions such as osteoporosis. Guided wave propagation in bone systems modeled as multi-layered tubular structures consisting of anisotropic bone filled with viscous marrow and surrounded by tissue is studied using the Semi Analytical Finite Element (SAFE) method. Effects of changes to cortical bone thickness and mechanical properties are investigated. An attempt is also made to consider bone anisotropy in the models.The results, validated by experiments with bone phantoms, show that material and geometric condition strongly impacts the velocity of guided waves supported in the bone system. Identification of optimal guided wave modes for practical assessment is also discussed.

On a framework for generating PoD curves assisted by numerical simulations

Abstract: The Probability of Detection (PoD) curve method has emerged as an important tool for the assessment of the performance of NDE techniques, a topic of particular interest to the nuclear industry where inspection qualification is very important. The conventional experimental means of generating PoD curves though, can be expensive, requiring large data sets (covering defects and test conditions), and equipment and operator time. Several methods of achieving faster estimates for PoD curves using physics-based modelling have been developed to address this problem. Numerical modelling techniques are also attractive, especially given the ever-increasing computational power available to scientists today. Here we develop procedures for obtaining PoD curves, assisted by numerical simulation and based on Bayesian statistics. Numerical simulations are performed using Finite Element analysis for factors that are assumed to be independent, random and normally distributed. PoD curves so generated are compared with experiments on austenitic stainless steel (SS) plates with artificially created notches. We examine issues affecting the PoD curve generation process including codes, standards, distribution of defect parameters and the choice of the noise threshold. We also study the assumption of normal distribution for signal response parameters and consider strategies for dealing with data that may be more complex or sparse to justify this. These topics are addressed and illustrated through the example case of generation of PoD curves for pulse-echo ultrasonic inspection of vertical surface-breaking cracks in SS plates.

Investigation of Ultrasonic Feature Guided Waves for the Monitoring of Structural Bends

Abstract: This paper investigates the inspection and monitoring structural bends using a special ultrasonic bend-guided wave, which concentrates the energy in and around the bend. Modal studies are carried out using the Semi-Analytical Finite Element (SAFE) method, while 3D finite element (FE) simulations are used to gain visualization of results and also obtain cross-validation. Our studies reveal, perhaps for the first time, the possibility of bend-guided modes of the shear-horizontal (SH) family, in addition those of the Rayleigh-Lamb family reported earlier in the literature. This mode has attractive properties including low attenuation and limited dispersion. We investigate effects of plate thickness and bend radius on the physics of FGW in bends, arguing the strong role of geometry and curvature effects in causing mode confinement. Experiments have also been carried out to validate the existence of such bend-guided mode. doi: 10.12783/SHM2015/83