INSPECTION BY ULTRASONIC TOMOGRAPHY (UT) LEADING TREND IN WELDING JOINT MONITORING

Authors

  • Noor Amizan Abd. Rahman Protom-i Research Group, Innovative Engineering Research Alliance, Control and Mechatronic Engineering Department, Universiti Teknologi Malaysia, 81310 UTM Johor Bahru, Malaysia
  • Ruzairi Abdul Rahim Protom-i Research Group, Innovative Engineering Research Alliance, Control and Mechatronic Engineering Department, Universiti Teknologi Malaysia, 81310 UTM Johor Bahru, Malaysia
  • Nor Muzakkir Nor Ayob Protom-i Research Group, Innovative Engineering Research Alliance, Control and Mechatronic Engineering Department, Universiti Teknologi Malaysia, 81310 UTM Johor Bahru, Malaysia
  • Jaysuman Pusppanathan Protom-i Research Group, Innovative Engineering Research Alliance, Control and Mechatronic Engineering Department, Universiti Teknologi Malaysia, 81310 UTM Johor Bahru, Malaysia
  • Fazlul Rahman Mohd Yunus Protom-i Research Group, Innovative Engineering Research Alliance, Control and Mechatronic Engineering Department, Universiti Teknologi Malaysia, 81310 UTM Johor Bahru, Malaysia
  • Mohd Hafiz Fazalul Rahiman School of Mechatronic Engineering Universiti Malaysia Perlis, Malaysia
  • Nasarudin Ahmad Protom-i Research Group, Innovative Engineering Research Alliance, Control and Mechatronic Engineering Department, Universiti Teknologi Malaysia, 81310 UTM Johor Bahru, Malaysia
  • Anita Ahmad Protom-i Research Group, Innovative Engineering Research Alliance, Control and Mechatronic Engineering Department, Universiti Teknologi Malaysia, 81310 UTM Johor Bahru, Malaysia
  • Mohd Amri Md Yunus Protom-i Research Group, Innovative Engineering Research Alliance, Control and Mechatronic Engineering Department, Universiti Teknologi Malaysia, 81310 UTM Johor Bahru, Malaysia
  • Khairul Hamimah Abas Protom-i Research Group, Innovative Engineering Research Alliance, Control and Mechatronic Engineering Department, Universiti Teknologi Malaysia, 81310 UTM Johor Bahru, Malaysia
  • Leow Pei Ling Protom-i Research Group, Innovative Engineering Research Alliance, Control and Mechatronic Engineering Department, Universiti Teknologi Malaysia, 81310 UTM Johor Bahru, Malaysia
  • Zulkarnay Zakaria School of Mechatronic Engineering Universiti Malaysia Perlis, Malaysia

DOI:

https://doi.org/10.11113/jt.v77.6416

Keywords:

Welding joint, non destructive testing by ultrasonic tomography and 3D imaging

Abstract

Welding work is a connection process between the structure and the materials. This process is used in the construction, maintenance and repair especially mechanical engineering. This study discusses the type of welding used in the industry, mainly involving the pipeline welds. On-demand need to every work process when finishing weld requires quality tests to ensure compliance to the standards required. Monitoring through the display image has long been used in Non-Destructive Testing (NDT). Various methods of monitoring used in NDT focused on Ultrasonic Tomography (UT) as a method used in NDT and as an option for the future. Previous imaging result was in two-dimensional (2D) and then upgraded to a three-dimensional image (3D). Besides, there is potential of 3D imaging beyond the existing limits in terms of size, material thickness, especially for welding steel pipes. Achievement through research of existing pipe size so far outside diameter of 200 mm and a thickness of 5.8 mm should be limited in view of the obstacles to enhanced image resolution is less effective when compared to other tomography methods.

References

L. P. Connor. 1987. Welding Handbook. 1.

M. Imam, K. Biswas, V. Racherla. 2013. On Use Of Weld Zone Temperatures For Online Monitoring Of Weld Quality In Friction Stir Welding Of Naturally Aged Aluminium Alloys. Mater. Des. 52: 730-739.

K. Pal and S. K. Pal. 2010. Study Of Weld Joint Strength Using Sensor Signals for Various Torch Angles in Pulsed MIG Welding.CIRP J. Manuf. Sci. Technol. 3(1): 55-65.

E. J. LaCourse, S. Perally, R. M. Morphew, J. V. Moxon, M. Prescott, D. J. Dowling, S. M. O’Neill, A. Kipar, U. Hetzel, E. Hoey, R. Zafra, L. Buffoni, J. Arévalo, and P. M. Brophy. The Sigma Class Glutathione Transferase From The Liver Fluke Fasciola Hepatica. PLoS Negl. Trop. Dis. 6(5).

W. Huang and R. Kovacevic. 2011. A Laser-Based Vision System For Weld Quality Inspection. Sensors. 11(1): 506-521

N. A. C. Lah, A. Ali, N. Ismail, L. P. Chai, A. A. Mohamed. 2010. The Effect of Controlled Shot Peening on Fusion Welded Joints. Mater. Des. 31(1): 312-324.

M. Mahdavi Shahri, R. Sandström. 2012. Effective Notch Stress and Critical Distance Method to Estimate the Fatigue Life of T and Overlap Friction Stir Welded Joints. Eng. Fail. Anal. 25: 250-260.

S. D. Raymond, P. M. Wild, C. J. Bayley. 2004. On Modeling of The Weld Line in Finite Element Analyses of Tailor Welded Blank Forming Operations. Journal of Materials Processing Technology. 147(1): 28-37.

T. L. Teng, C. P. Fung, P. H. Chang. 2002. Effect of Weld Geometry and Residual Stresses on Fatigue in Butt Welded Joints. 2002. Int. J. Press. Vessel. Pip. 79(7): 467-482.

H. Long, D. Gery, A. Carlier, P. G. Maropoulos. 2009. Prediction of Welding Distortion in Butt Joint of Thin Plates. Mater. Des. 30(10): 4126-4135.

M. Dinham, G. Fang. 2014. Detection of Fillet Weld Joints Using an Adaptive Line Growing Algorithm for Robotic Arc Welding. Robot. Comput. Integr. Manuf. 30(3): 229-243.

B. Mellor, R. C. Rainey, N. Kirk. 1999. The Static Strength of End and T Fillet Weld Connections. Materials & Design. 20(4): 193-205.

D. Gery, H. Long, P. Maropoulos. 2005. Effects of Welding Speed, Energy Input and Heat Source Distribution on Temperature Variations in Butt Joint Welding. J. Mater. Process. Technol. 167(2-3): 393-401.

T. Lim, H. G. Ryu, C.-W. Jung, Y. Jeon, J.-H. Bahk. 2012. Effect of The Bevel Direction of Puncture Needle on Success Rate and Complications During Internal Jugular Vein Catheterization. Critical Care Medicine. 40(2): 491-494.

C. J. Chang, T. M. Lee, J. K. Liu. 2013. Effect Of Bracket Bevel Design And Oral Environmental Factors On Frictional Resistance. Angle Orthod. 83(6): 956-965.

S. Paddea, J. A. Francis, A. M. Paradowska, P. J. Bouchard, I. A. Shibli. 2012. Residual Stress Distributions In A P91 Steel-Pipe Girth Weld Before And After Post Weld Heat Treatment. Mater. Sci. Eng. A. 534: 663-672.

K. Pal., S. K. Pal. 2011. Effect Of Pulse Parameters On Weld Quality In Pulsed Gas Metal Arc Welding: A Review. Journal of Materials Engineering and Performance. 20(6): 918-931.

J. da Silva., J. M. Costa., A. Loureiro., J. M. Ferreira. 2013. Fatigue Behaviour Of AA6082-T6 MIG Welded Butt Joints Improved By Friction Stir Processing. Mater. Des. 51: 315-322.

G. K. Ahiale., Y. J. Oh. 2014. Microstructure And Fatigue Performance Of Butt-Welded Joints In Advanced High-Strength Steels. Mater. Sci. Eng. A. 597: 342-348.

D. Frank., H. Remes., J. Romanoff. 2013. J-Integral-Based Approach To Fatigue Assessment Of Laser Stake-Welded T-Joints. Int. J. Fatigue. 47: 340-350.

L. Cui, X. Yang., G. Zhou., X. Xu., Z. Shen. 2012. Characteristics Of Defects And Tensile Behaviors On Friction Stir Welded AA6061-T4 T-Joints. Mater. Sci. Eng. A. 543: 58-68.

M. Bin Lin., K. Gao., C. J. Wang., A. A. Volinsky., 2012. Failure Analysis Of The Oil Transport Spiral Welded Pipe. Eng. Fail. Anal. 25: 169-174.

A. C. F. Silva., D. F. O. Braga., M. A. V. de Figueiredo., P. M. G. P. Moreir. 2014. Friction Stir Welded T-Joints Optimization. Mater. Des. 55: 120-127.

S. Hassanifard., S. Rash Ahmadi., M. Mohammad Pour. 2013. Weld Arrangement Effects On The Fatigue Behavior Of Multi Friction Stir Spot Welded Joints. Materials & Design. 44: 291-302.

W. Lin., T. Yoda., N. Taniguchi., S. Satake., H. Kasano. 2014. Preventive Maintenance On Welded Connection Joints In Aged Steel Railway Bridges. J. Constr. Steel Res. 92: 46-54.

A. Ambroziak., M. Korzeniowski., P. Kustroń., M. Winnicki. 2011. Friction Welding Of Niobium And Tungsten Pseudoalloy Joints. Int. J. Refract. Met. Hard Mater. 29: 499-504.

A. Ambroziak. 2010Friction Welding Of Titanium-Tungsten Pseudoalloy Joints. J. Alloys Compd. 506(2): 761-765.

H. Bang., H. Bang., G. Jeon., I. Oh., C. Ro. 2012. Gas Tungsten Arc Welding Assisted Hybrid Friction Stir Welding Of Dissimilar Materials Al6061-T6 Aluminum Alloy And STS304 Stainless Steel. Mater. Des. 37: 48-55.

F. Balle., D. Eifler. 2012. Statistical Test Planning For Ultrasonic Welding Of Dissimilar Materials Using The Example Of Aluminum-Carbon Fiber Reinforced Polymers (CFRP) Joints. Materwiss. Werksttech. 43: 286-292.

J. A. Al-Jarrah., S. Swalha., T. A. Mansour., M. Ibrahim., M. Al-Rashdan., D. A. Al-Qahsi. 2014. Welding Equality And Mechanical Properties Of Aluminum Alloys Joints Prepared By Friction Stir Welding. Mater. Des. 56: 929-936.

M. Simoncini., A. Forcellese. 2012. Effect Of The Welding Parameters And Tool Configuration On Micro- And Macro-Mechanical Properties Of Similar And Dissimilar Fswed Joints In AA5754 And AZ31 Thin Sheets. Mater. Des. 41: 50-60.

R. Cao., S. S. Zhu., W. Feng., Y. Peng., F. Jiang., W. S. Du., Z. L. Tian., J. H. Chen. 2011. Effects Of Weld Metal Property And Fraction On The Toughness Of Welding Joints Of A 8%Ni 980 Mpa High Strength Steel. J. Mater. Process. Technol. 211: 759-772.

N. V. Dudamell., I. Ulacia., F. Gálvez., S. Yi, J. Bohlen., D. Letzig., I. Hurtado., M. T. Pérez-Prado. 2012. Influence Of Texture On The Recrystallization Mechanisms In An AZ31 Mg Sheet Alloy At Dynamic Rates. Mater. Sci. Eng. A. 532: 528-535.

T. S. Balasubramanian, M. Balakrishnan, V. Salasubramanian, M. A. M. Manickam. 2011. Influence Of Welding Processes On Microstructure, Tensile And Impact Properties Of Ti-6Al-4V Alloy Joints. Trans. Nonferrous Met. Soc. China (English Ed). 21: 1253-1262.

H. Bisadi., A. Tavakoli., M. Tour Sangsaraki., K. Tour Sangsaraki. 2013. The Influences Of Rotational And Welding Speeds On Microstructures And Mechanical Properties Of Friction Stir Welded Al5083 And Commercially Pure Copper Sheets Lap Joints. Mater. Des. 43: 80-88.

A. K. Lakshminarayanan, S. Malarvizhi, V. Balasubramanian. 2011. Developing Friction Stir Welding Window For AA2219 Aluminium Alloy. Trans. Nonferrous Met. Soc. China (English Ed.). 21: 2339-2347.

H. Bouzaiene, M. A. Rezgui, M. Ayadi, A. Zghal. 2012. Correlation Between Welding And Hardening Parameters Of Friction Stir Welded Joints Of 2017 Aluminum Alloy. Trans. Nonferrous Met. Soc. China (English Ed.). 22: 1064-1072

S. Elangovan., K. Prakasan., V. Jaiganesh. 2010. Optimization Of Ultrasonic Welding Parameters For Copper To Copper Joints Using Design Of Experiments. The International Journal of Advanced Manufacturing Technology. 51: 163-171.

T. H. Kim., J. Yum., S. J. Hu., J. P. Spicer., J. A. Abell. 2011. Process Robustness Of Single Lap Ultrasonic Welding Of Thin, Dissimilar Materials. CIRP Ann.-Manuf. Technol. 60: 17-20.

M. J. Troughton. 2009. Ultrasonic Welding in Handbook of Plastics Joining-A Practical Guide. 2009: 15-35.

E. Cerri and P. Leo. 2011. Mechanical Properties Evolution During Post-Welding-Heat Treatments Of Double-Lap Friction Stir Welded Joints. Mater. Des. 32: 3465-3475.

S. Heinz., G. Wagner., D. Eifler. 2012. Ultrasonic Welding Of Wires And Cables. JOM. 64: 421-426.

G. Wagner., F. Balle., D. Eifler. 2012. Ultrasonic Welding Of Hybrid Joints. JOM. 64: 401-406.

Y. Javadi., M. A. Najafabadi. 2013. Comparison Between Contact And Immersion Ultrasonic Method To Evaluate Welding Residual Stresses Of Dissimilar Joints. Mater. Des. 47: 473-482.

A. Turó., J. A. Chávez., M. J. García-Hernández., A. Bulkai., P. Tomek., G. Tóth., A. Gironés., J. Salazar. 2013. Ultrasonic Inspection System For Powder Metallurgy Parts. Meas. J. Int. Meas. Confed. 46: 1101-1108.

T. W. Liao., J. Ni.1996. An Automated Radiographic NDT System For Weld Inspection: Part I-Weld Extraction. NDT E Int. 29(3): 157-162.

B. G. Bubar. 2011. Welding and NDT in Pipeline Planning and Construction Field Manual. 357-378.

Z. Zhu., K. Y. Lee., X. Wang. 2012. Ultrasonic Welding Of Dissimilar metals, AA6061 and Ti6Al4V. Int. J. Adv. Manuf. Technol. 59: 5(8): 569-574.

M. Thornton., L. Han., M. Shergold. 2012. Progress In NDT Of Resistance Spot Welding Of Aluminium Using Ultrasonic C-Scan.NDT E Int.48: 30–38

G. Almeida., J. Gonzalez., L. Rosado., P. Vilaça., T. G. Santos. 2013. Advances In NDT And Materials Characterization By Eddy Currents. Procedia CIRP. 7: 359-364.

B. W. Drinkwater, P. D. Wilcox. 2006. Ultrasonic Arrays For Non-Destructive Evaluation: A Review. NDT and E International. 39: 525-541

A. Lhémery., P. Calmon., I. Lecœur-Taïbi., R. Raillon., L. Paradis. 2000. Modeling Tools For Ultrasonic Inspection Of Welds. NDT E Int. 33(7): 499-513.

W. Ke., M. Castaings., C. Bacon. 2009. 3D Finite Element Simulations of An Air-Coupled Ultrasonic NDT System. NDT E Int. 42(6): 524-533.

B. Li., Y. Shen., W. Hu. 2011. The Study On Defects In Aluminum 2219-T6 Thick Butt Friction Stir Welds With The Application Of Multiple Non-Destructive Testing Methods. Mater. Des. 32(4): 2073-2084.

J. Ye., H. J. Kim., S. J. Song., S. S. Kang., K. Kim., M. H. Song. 2011. Model-Based Simulation Of Focused Beam Fields Produced By A Phased Array Ultrasonic Transducer In Dissimilar Metal Welds. NDT E Int. 44(3): 290-296.

M. Spies., H. Rieder. 2010. Synthetic Aperture Focusing Of Ultrasonic Inspection Data To Enhance The Probability Of Detection Of Defects In Strongly Attenuating Materials. NDT E Int. 43(5): 425-431.

G. R. Lockwood., J. R. Talman., S. S. Brunke. 1998. Real-Time 3-D Ultrasound Imaging Using Sparse Synthetic Aperture Beamforming. IEEE Trans. Ultrason. Ferroelectr. Freq. Control. 45(4): 980-988.

A. N. Sinclair., J. Fortin., B. Shakibi., F. Honarvar., M. Jastrzebski., M. D. C. Moles. 2010. Enhancement of Ultrasonic Images for Sizing of Defects By Time-Of-Flight Diffraction. NDT E Int. 43(3): 258-264.

L. Capineri., H. G. Tattersall., M. G. Silk., J. A. G. Temple. 1992. Time-Of-Flight Diffraction Tomography For NDT Applications. Ultrasonics. 30(5): 275-288.

K. J. Dharmaraj, C. D. Cox, A. M. Strauss, and G. E. Cook. 2014. Ultrasonic Thermometry For Friction Stir Spot Welding. Measurement. 49: 226-235.

E. Ginzel., H. Van Dijk., M. Hoff. 2007. TOFD Enhancement to Pipeline Girth Weld Inspection. NDTnet. 3(4): 1-10.

A. Al-Ataby., W. Al-Nuaimy., O. Zahran. 2010. Towards Automatic Flaw Sizing Using Ultrasonic Time-Of-Flight Diffraction. Insight Non-Destructive Test. Cond. Monit. 52(7): 366-371.

T. Stepinski. 2010. Synthetic Aperture Focusing Techniques For Ultrasonic Imaging Of Solid Objects. Synth. Aperture Radar.: 438–441

M. H. Skjelvareid., T. Olofsson., Y. Birkelund., Y. Larsen. 2011. Synthetic Aperture Focusing Of Ultrasonic Data From Multilayered Media Using An Omega-K Algorithm.IEEE Trans. Ultrason. Ferroelectr. Freq. Control. 58(5): 1037-1048.

M. H. Skjelvareid., Y. Birkelund., Y. Larsen. 2013. Internal Pipeline Inspection Using Virtual Source Synthetic Aperture Ultrasound Imaging. NDT E Int. 54: 151-158.

J. F. Robillard., J. Bucay., P. A. Deymier., A. Shelke., K. Muralidharan., B. Merheb., J. O. Vasseur., A. Sukhovich., J. H. Page. 2011. Resolution Limit Of A Phononic Crystal Superlens. Phys. Rev. B-Condens. Matter Mater. Phys. 83(22).

J. H. Chang., T. K. Song. 2011. A New Synthetic Aperture Focusing Method To Suppress The Diffraction Of Ultrasound. IEEE Trans. Ultrason. Ferroelectr. Freq. Control. 58(2): 327-337.

M. Kobayashi., K.-T. Wu., J.-L. Shih., C.-K. Jen. S. E. Kruger. 2010. Flexible Ultrasonic Transducers For Structural Health Monitoring Of Metals And Composites. Proc. SPIE. 7648(1): 76480W–76480W–10.

J. L. Shih., K. T. Wu., C. K. Jen., C. H. Chiu., J. C. Tzeng., J. W. Liaw. 2013. Applications Of Flexible Ultrasonic Transducer Array for Defect Detection At 150°C. Sensors (Switzerland). 13(1): 975-983.

C. C. Ho., J. J. He., T. Y. Liao. 2012. On-Line Estimation Of Laser-Drilled Hole Depth Using A Machine Vision Method. Sensors (Switzerland). 12(8): 10148-10162.

B. Dai., H. Zhang., S. Sheng., J. Dong., Z. Xie., D. Tang. 2007. An Ultrasonic In-Line Inspection System On Crude Oil Pipelines. Proceedings of the 26th Chinese Control Conference, CCC. 2007: 199-203.

X. Li., W. Yu., X. Lin., S. S. Iyengar. 2012. On Optimizing Autonomous Pipeline Inspection. IEEE Trans. Robot. 28(1): 223-233.

M. Ravan., R. K. Amineh., S. Koziel., N. K. Nikolova., J. P. Reilly. 2010. Sizing Of 3-D Arbitrary Defects Using Magnetic Flux Leakage Measurements. IEEE Trans. Magn. 46(4): 1024-1033.

A. Bouchalkha., M. S. Hamad., K. Al-Beloushi., M. Al-Qayedi., K. Al-Hammadi. 2011. Design Of An Oil Pipe Inner Surface Inspection System. IEEE GCC Conference and Exhibition. 29-32.

S. Mukhopadhyay., G. P. Srivastava. 2000. Characterization Of Metal Loss Defects From Magnetic Flux Leakage Signals With Discrete Wavelet Transform. NDT E Int. 33(1): 57-65.

P. S. Tofts., A. G. Kermode. 1991. Measurement Of The Blood-Brain Barrier Permeability And Leakage Space Using Dynamic MR Imaging. 1. Fundamental Concepts. Magn. Reson. Med. 17(2): 357-367.

J. Zhang., Z. Ouyang., M. C. Duffy., M. A. E. Andersen. W. G. Hurley. 2013. Leakage Inductance Calculation For Planar Transformers With A Magnetic Shunt. IEEE Energy Conversion Congress and Exposition. 643-648.

V. Babbar., L. Clapham. 2003. Residual Magnetic Flux Leakage: A Possible Tool For Studying Pipeline Defects. J. Nondestruct. Eval. 22(4): 117-125.

G. Yamahata., T. Kodera., H. O. H. Churchill., K. Uchida., C. M. Marcus., S. Oda. 2012. Magnetic Field Dependence Of Pauli Spin Blockade: A Window Into The Sources Of Spin Relaxation In Silicon Quantum Dots. Phys. Rev. B-Condens. Matter Mater. Phys. 86(11).

X. Zhang., Z. Ma., Y. Hu., J. Huang. 2008. A Novel Robot System For Surface Inspection And Diameter Measurement Of Large Size Pipes. IEEE International Conference on Industrial Informatics (INDIN). 1717-1721.

G. Bright., D. Ferreira., R. Mayo. 1997. Automated Pipe Inspection Robot. Industrial Robot: An International Journal. 24 (4): 285 – 289

I. A. Chaves and R. E. Melchers. 2011. Pitting Corrosion In Pipeline Steel Weld Zones. Corros. Sci. 53(12): 4026-4032.

B. Physics., S. Circuits. 2010. LabView Programming. Training. 4-5.

C. H. Lee., K. H. Chang. 2014. Comparative Study On Girth Weld-Induced Residual Stresses Between Austenitic And Duplex Stainless Steel Pipe Welds. Appl. Therm. Eng. 63(1): 140-150.

J. Moysan., M. Ploix. 2009. Advances In Ultrasonic Testing Of Austenitic Stainless Steel Welds. Towards A 3D Description Of The Material Including Attenuation And Optimisation By Inversion. Ultrasonic Wave. 128: 15-24.

C. J. Martín., O. Martínez-Graullera., D. Romero., R. T. Higuti., L. G. Ullate. 2010. Linear Scanning Method Based On The SAFT Coarray. Aip Conference Proceedings. 1211: 2023-2030.

B. Campagne., D. Levesque., A. Blouin., B. Gauthier., M. Dufour., J. P. Monchalin. 2002. Laser-Ultrasonic Inspection Of Steel Slabs Using SAFT Processing. AIP Conf. Proc. 615A: 340-347.

J. M. Hansen., J. A. Jensen. 2012. Compounding In Synthetic Aperture Imaging. IEEE Trans. Ultrason. Ferroelectr. Freq. Control. 59(9): 2054-65.

A. Barkefors. 2010. 3D Synthetic Aperture Technique for Ultrasonic Imaging. UPTEC F10 017.

Downloads

Published

2015-11-24

How to Cite

INSPECTION BY ULTRASONIC TOMOGRAPHY (UT) LEADING TREND IN WELDING JOINT MONITORING. (2015). Jurnal Teknologi (Sciences & Engineering), 77(17). https://doi.org/10.11113/jt.v77.6416