NDE Inspection FMC and TFM

Transcription

1 NDE Inspection FMC and TFM

2 Homogeneous Material Modelling o Simulations replicating an experimental Full Matrix Capture (FMC) ultrasonic array inspection of a calibration block o Total Focusing Method (TFM) imaging algorithm used to allow a direct back to back comparison with experimental results o 2D models along with a full 3D model to simulate inspection of linear and volumetric defects o Results demonstrate validity and feasibility of PZFlex simulations 15 mm plate 4mm defect 2D Model of Calibration Block with 4 Transducer Inspection Positions

3 Experimental Setup o 128 Element Array o 2.25MHz Centre Frequency o 0.75mm Element Pitch o Harfang Stainless Steel Calibration Block with 1, 1.5 and 2 mm side drilled holes o Four angle drilled holes at 15, 30, 45 and 60 degrees o 4 FMC data sets collected with different transducer locations 4mm defect 15 mm plate

4 Video of 2D Simulation 4mm defect 15 mm plate

5 2D Simulation vs Experiment Transducer Position 1 4mm defect 15 mm plate Experiment 2D Simulation

6 2D Simulation vs Experiment Transducer Position 2 4mm defect 15 mm plate Experiment 2D Simulation

7 2D Simulation vs Experiment Transducer Position 3 4mm defect Experiment 2D Simulation

8 2D Simulation vs Experiment Transducer Position 4 4mm defect 15 mm plate Experiment 2D Simulation

9 3D Model o Full 3D model created to investigate inspection of volumetric defects o CAD model importation o Approx. 87 million elements o 5 hours runtime per simulation using 7.2GB memory on i5 laptop o Message Passing Interface (MPI) reduced run time by 5x o Parallelisation on PZFlexCloud gave full dataset in 5 hours 4mm defect 15 mm plate

10 3D Simulation vs Experiment Transducer Position 2 4mm defect 15 mm plate Experiment 3D Simulation

11 Heterogeneous Material Modelling o Extension of modelling method to simulate FMC inspection of an anisotropic weld o Electron Back Scatter Diffraction (EBSD) image imported into PZFlex o Weld inspection is highly frequency dependent due to grain structure o Simulations performed add to previous studies on weld o Aim of this work is to perform full 3D models to produce better representations of practical inspections EBSD Data 15 mm plate

12 Heterogeneous Material Modelling o An EBSD dataset was used, originally generated as part of the UK Technology Strategy Board DISSIMILAR Project ( o Previously presented work [1] highlighted the importance of frequency selection for inspection of the weld o Transmission Spectra indicates the attenuation variation due to different frequencies Transmission Spectra [1] Harvey, G., Tweedie, A., Carpentier, C., Reynolds, P., Thompson, D. O., & Chimenti, D. E. (2011, June). Finite element 15 analysis mm plate of ultrasonic phased array inspections on anisotropic welds. In AIP Conference Proceedings-American Institute of Physics (Vol. 1335, No. 1, p. 827).

13 Heterogeneous Material Modelling o FMC performed on weld using different transducer properties o Frequencies of 0.5, 1 & 1.5 MHz used o Element pitch constant at λ/2 o Number of elements varied to create array of length equal to ½, 1 & 1½ weld width ½ weld width length of array, no defect o Simulations repeated with a single central side drilled hole defect of 1mm radius 15 mm plate 1 ½ weld width length of array, with defect

14 No Defect in Weld ½ Weld Width Weld Width 1 ½ Weld Width 0.5 MHz 1.0 MHz 1.5 MHz

15 Defect in Weld ½ Weld Width Weld Width 1 ½ Weld Width 0.5 MHz 1.0 MHz 1.5 MHz

16 Output Metrics o Individual simulation runtimes: seconds for 0.5MHz and 1MHz while 1.5MHz took 2 minutes o Time to generate FMC data sets varied between 4 and 138 minutes o Results emphasize frequency dependence of weld inspection and back scatter generated from grain structure 15 mm plate

17 Conclusions o Current work has provided an extremely strong foundation o Validation of the modelling approach has been achieved through replicating experimental inspections and showing excellent correlation o Extension of the modelling allowed for simulation of FMC inspections of an anisotropic weld o Initial simulations highlight importance of frequency selection and demonstrate back scatter effects of weld inspection 15 mm plate

18 Simulation Metrics Model 2D Inspection 3D Inspection Elements 600,000 87,000,000 Runtime 45 s* Total Runtime Memory (RAM) *Per simulation on laptop i5 laptop 5 hrs 1hr (MPI) 96 min** 5 hrs** 2D Aniso. Weld Up to 1,276, s / 2 mins 4mins / 2 hrs MB 7.2 GB 400 MB **Parellelisation reduces Total Runtime to Runtime for full dataset