2012 18th WCNDT Durban - Plenary talk · Plenary Address Plenary Address –––– 18 WCNDT 18...
Transcript of 2012 18th WCNDT Durban - Plenary talk · Plenary Address Plenary Address –––– 18 WCNDT 18...
NDE Approaches for Enhanced Performance and NDE Approaches for Enhanced Performance and Mitigation of Risks in Demanding TechnologiesMitigation of Risks in Demanding Technologies
BaldevBaldev RajRaj
E-mail: [email protected]
PresidentPresident --Research PSG InstitutionsResearch PSG InstitutionsPresidentPresident --Research PSG InstitutionsResearch PSG InstitutionsPresident Indian National Academy of EngineeringPresident Indian National Academy of Engineering
President, International Institute of WeldingPresident, International Institute of WeldingJC Bose, National Fellow; DSTJC Bose, National Fellow; DST
CoimbatoreCoimbatore
Plenary Address Plenary Address Plenary Address Plenary Address Plenary Address Plenary Address Plenary Address Plenary Address –––––––– 18 WCNDT18 WCNDT18 WCNDT18 WCNDT18 WCNDT18 WCNDT18 WCNDT18 WCNDT--------2012, Durban, South Africa, 162012, Durban, South Africa, 162012, Durban, South Africa, 162012, Durban, South Africa, 162012, Durban, South Africa, 162012, Durban, South Africa, 162012, Durban, South Africa, 162012, Durban, South Africa, 16thththththththth April, 2012April, 2012April, 2012April, 2012April, 2012April, 2012April, 2012April, 2012
Challenges ….. Challenges …..
� Increasing demands on clean and competitive energy, water, agriculture and healthcare. (These demands are to be met with ethics and equity)
� Longetivity – old age problems – newer strains of diseases
� Ageing assets and new high performing assets
� Globalisation of economies – increased competitions – to be met with competence, innovations and ethics
� Increased social and work stresses
� Human resources (engineers) to meet the challenges
Directions of Technology Directions of Technology
� Technologies performing at frontiers of limits of performance
� Very large structures plants to nano devices
� Design, analysis, virtual reality, health diagnosis, Asset Management
� Innovations in all stages of life cycle of technology (evolutionary, paradigm changes, cascade, …innovation ecosystem)
� Newer materials processes and performance (modelling and simulation, advanced characterization, testing and analysis for extreme conditions)
� Advanced sensors, wireless networks, embedded systems, on-line measurements and their analysis.
Management……Management……� Simple and Robust management principles and practices
� Paradigm shifts in management concepts(fast, diverse, organic vs inorganic growth,…)
� Interdisciplinary decisions : A wide spectrum in cultures of countries, religions, competences, bureaucracies, priorities.
� Ethics, Equity
� Engineering Challenge – Fractured linkages leading to weakness in decisions
Accidents ……Accidents ……
Challenger disaster, Jan 1986 Concorde disaster – July 2000
Bhopal gas tragedy Dec. Bhopal gas tragedy Dec. 19841984
Fukushima accidents, Mar. 2011Gulf of Mexico Apr. 2010
Prediction, Management of black swan, fat tail, low probability but high risk accident scenarios Prediction, Management of black swan, fat tail, low probability but high risk accident scenarios
� Improper Design and Materials (Challenger),
� Inadequate safety and regulatory practices (Bhopal )
� Improper PSI, ISI, TQM (Gulf of Mexico)
Analysis……Analysis……
� Inadequate defense in depth and lack of organisatio naldecision making (Fukushima)
Common Thread in all the above ….� Measurements(relevance,adequacy,sensitivity,robustn ess)
� Inadequate analysis and correlation to performance in steady state and accident scenarios
DNA of Plant longetivity with risk mitigations….DNA of Plant longetivity with risk mitigations….
Steady State Steady State PerformancePerformance
Extended life Extended life with robust with robust
performance performance
Knowledge of Knowledge of AssetAsset
OnOn--line and line and Periodic inPeriodic in--situ situ
Monitoring using Monitoring using Measurements Measurements performance performance and enhanced and enhanced
productivityproductivity
Probabilistic + Deterministic Probabilistic + Deterministic Risk AnalysisRisk Analysis
Review+ Review+ FeedbackFeedback
Monitoring using Monitoring using advanced advanced
technologies technologies
Minimum Minimum Excursions Excursions
and Outagesand Outages
Measurements Measurements ++
NDE NDE PlanPlan
ImplementImplement
DemonstrateDemonstrate
MeasureMeasure
Analysis Analysis
ImproveImprovewithwith
FeedFeed--back back
Infrastructure and
Facilities
Multi NDE and Fusion ofimages
and signals
Nurturing relevant Human
Resources
NDE
Synergy of Expertise and facilities
NDE Waves ….
Sensors and Instrumentation
Basic Physics Materials Science
Modelling and Simulation
NDE
Challenges in newer Materials – design,
development and manufacturing
Enhanced Capability….
1010
“ “ The country that learns to build The country that learns to build
breeder reactor would have solved breeder reactor would have solved
its energy problems for ever its energy problems for ever ””
“ The country which first develops “ The country which first develops
a breeder reactor will have a great a breeder reactor will have a great
competitive advantage in Atomic competitive advantage in Atomic
Energy ” Energy ” -- India made an early entry to India made an early entry to
Nuclear EnergyNuclear Energy
A Visionary’s Dream on Nuclear A Visionary’s Dream on Nuclear Sodium Cooled Reactors . . . . Sodium Cooled Reactors . . . .
Enrico Fermi Nuclear Generating StationEnrico Fermi Nuclear Generating Station1901 1901 -- 19541954
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Equity through TechnologyEquity through Technology
Nuclear EnergyNuclear EnergyBreeding ratio: “ . . . it obviously must be great er Breeding ratio: “ . . . it obviously must be great er
than one ”. than one ”.
“ The serious objection to these fast chain piles i s “ The serious objection to these fast chain piles i s
the removal of heat ”. the removal of heat ”.
“ The coolant for this type of pile would be a “ The coolant for this type of pile would be a
bismuthbismuth--lead alloy and would flow downward lead alloy and would flow downward
through the pile between the static and rotating through the pile between the static and rotating
rods. The possibility of using liquid sodium in rods. The possibility of using liquid sodium in
place of bismuthplace of bismuth--lead should also be looked into ” . lead should also be looked into ”.
[ India pursues a vibrant Fast Reactor Program][ India pursues a vibrant Fast Reactor Program]
Enrico Fermi, Meeting in April 26, 1944 Enrico Fermi, Meeting in April 26, 1944 With Wigner, Szilard and Others on With Wigner, Szilard and Others on ::
“ How the Chain Reaction would be used for “ How the Chain Reaction would be used for the production of power ”the production of power ”
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FBR PROGRAMME IN INDIAFBR PROGRAMME IN INDIA
10 0907 08
06
04 05
03
11
1372
5
Ø11950
Future FBRFuture FBR
•• 1000 MWe1000 MWe
Credible confidence in
fuel cycle
Human resources
Human resources
25 years ofsuccessfuloperation
StateState--ofof--art art
conceptsconcepts
Innovative concepts
03
02 0112
FBTRFBTR•• 40 40 MWtMWt (13.5 (13.5 MWeMWe) )
•• Loop type reactor Loop type reactor
•• PuPuC C –– UCUC
•• Design: CEA, FranceDesign: CEA, France
Since 1985Since 1985……
PFBRPFBR•• 1250 MWt (500 MWe)1250 MWt (500 MWe)
•• Pool TypePool Type
•• UOUO22--PuOPuO22
•• Indigenous design and Indigenous design and constructionconstruction
•• To commission in 2012To commission in 2012
CFBRCFBR
•• 500 MWe500 MWe
•• Pool TypePool Type
•• UOUO22--PuOPuO22
•• Six units (3 twin units) Six units (3 twin units)
•• To commission in 2023To commission in 2023
•• Pool TypePool Type
•• Metallic fuel Metallic fuel
•• Serial Serial constructionconstruction
•• Beyond 2025Beyond 2025
Technological Challenges in FBRTechnological Challenges in FBRCompact Reactor Core With High Fissile ContentCompact Reactor Core With High Fissile Content
Use of Liquid Na as Coolant at high temperatures ( ~ 823 K) Use of Liquid Na as Coolant at high temperatures ( ~ 823 K)
Design and fabrication of Materials that can withstand intense neutron dose, temperature, and Design and fabrication of Materials that can withstand intense neutron dose, temperature, and loadings including Seismicloadings including Seismic
Reprocessing of highly active spent fuelReprocessing of highly active spent fuel
High Level waste management is very important for the success of Nuclear OptionHigh Level waste management is very important for the success of Nuclear Option
Achieving High Performance with
risk mitigation
Analysis based on Analysis based on ModellingModelling and and
SimulationSimulation
Our approaches to challenges …Our approaches to challenges …
Validation through Validation through accurate and accurate and
sensitive sensitive measurementsmeasurements
Technology Technology Development (1:1 or Development (1:1 or
scaled down scaled down models)models)
Knowledge Knowledge Management, Management,
feedback Design, feedback Design, Visionary ISIVisionary ISI
ISI of FBR ComponentsISI of FBR Components� In-Core Components
� Fuel subassemblies
� IHX, Roof slab
� Discharge pipe etc.
Issues - Access constraints, background radiation,
temp., opaque sodium thus limited possibility
for inspection
Approach - Stringent quality assurance (QA)Approach - Stringent quality assurance (QA)
Visual examination & under Sodium Ultrasonic’s
viewing employed
� Out-of-Core Components
� Main vessel / Safety vessel
� Steam generators / Sodium circuit pipes
� Concrete containment etc.
Issues: Access restrictions, temperature, time of inspection
Approach : Stringent QA +Advance NDE methods + Robotic devic es
developed for ISI
Visual Examination Visual Examination SystemSystem
Test Trolley Test Trolley developed developed
for for validation validation
Ultrasonic Test SystemUltrasonic Test System
DISHA ModelDISHA Model
DISHA DISHA AssemblyAssembly
�� Temperature during ISI Temperature during ISI -- 150 150
mm mm
�� Temperature during ISI Temperature during ISI -- 150 150
°°°°°°°°CC
�� MVMV--SV InterSV Inter--space space -- 300 300 ±± 50 50
mm mm
High Temperature Test High Temperature Test FacilityFacility
validation validation of of
kinematic kinematic parametersparameters
ISI marking on SV for ISI marking on SV for navigation of ISI devicenavigation of ISI device
Image of an artificial Image of an artificial crack through the Visual crack through the Visual
examination systemexamination system
Existing ISI Device for SG tubes Improved ISI device for SG tubes
Flexible Flexible
Robotic Robotic
armarm
Linear ActuatorsLinear Actuators
PulleysPulleys
Robot’s baseRobot’s base
ExciterExciter
ReceiverReceiver
Depleted UDepleted U
ringsrings
WINCHWINCH
Improved Device for ISI of SG Improved Device for ISI of SG tubes tubes
(SPATIAL HYPER REDUNDANT (SPATIAL HYPER REDUNDANT ROBOT)ROBOT)
Computer aided Computer aided simulation simulation
One set of One set of DiscDisc
Spider Robot On MockSpider Robot On Mock--up up
SG Tube SheetSG Tube Sheet
ISI Device being deployed in SG for ISI Device being deployed in SG for testingtesting
Remote Field Eddy Current Technique
DiscretisedDiscretised meshmeshFEM predicted poynting FEM predicted poynting vector plots of energyvector plots of energy
Detector Detector locationlocation
Optimal Optimal 1.8
2x 10
-5
700 Hz900 Hz1100 Hz
5x 10-6
ExciterExciter
0.9
1ModelExperimental 40% WL40% WL
RFEC technique PrincipleRFEC technique PrincipleRFEC technique involves detection of back entered lowRFEC technique involves detection of back entered low--frequency frequency
magnetic fields (energy) in tubes using a receiver coilmagnetic fields (energy) in tubes using a receiver coil
Optimal Optimal excitation excitation
frequency & frequency & detector location detector location
where RFEC where RFEC intensity is intensity is maximum maximum
determined using determined using 3D finite element 3D finite element
model and model and results validatedresults validated
1.9 2 2.1 2.2 2.3 2.4 2.5 2.6 2.7 2.80
0.2
0.4
0.6
0.8
1
1.2
1.4
1.6
1.8
Receiver coil location, ID (12.6 mm) times
Indu
ced
volta
ge in
the
Rec
eive
r co
il, V
olts
1100 Hz1300 Hz1500 Hz1100 Hz Experimental
800 900 1000 1100 1200 1300 1400
1
2
3
4
Frequency, Hz
RF
EC
Inte
nsity
, Vol
ts
RFEC zone for RFEC zone for detectordetector
Instrumentation difficultyInstrumentation difficulty
1100 Hz (optimum)1100 Hz (optimum)
50 100 150 200 250 300 350 400 450 500 5500
0.1
0.2
0.3
0.4
0.5
0.6
0.7
0.8
0.9
Scan position, mmR
FE
C A
mpl
itude
, V
olts
20% WL20% WL
10% WL10% WL
30% WL30% WL
40% WL40% WL
Model validation Model validation
S. Thirunavukkarasu, B.P.C. Rao, S. Mahadevan, T. Jayakumar, Baldev Raj, Z. Zeng, L. Udpa and S. S. Thirunavukkarasu, B.P.C. Rao, S. Mahadevan, T. Jayakumar, Baldev Raj, Z. Zeng, L. Udpa and S. Udpa, Journal of Research in NDE (USA), Vol. 20, 2009, pp 1Udpa, Journal of Research in NDE (USA), Vol. 20, 2009, pp 1--88
RTDS sensor developed for temperaturemeasurement on sodium loops (up to 700°C withspatial resolution of 1 m and temp. resolution of5°, limited by laser pulse width)
Fiber Bragg gratings designed and developed forstrain measurement on a test loop
Development of Optical Fiber based Raman Distributed Temperature (RTDS) Sensor
Acrylic ~ 100ºCPolyamide ~ 300ºC
Pulse Laser
Thermally influenced
� Leak detection is possible. For technology demonstration,controlled leaks were simulated using hot water as coolant.
�Spatial, statistical and temp. dependent errors analyzed t oimprove the leak detection capability in coolant loops ofreactors. Test loop for testing
molecular vibrationscause Raman backscattered light whoseintensity and arrivaltime are used fortemperature andlocation monitoring Single fiber grid was used to increase
the spatial resolution up to 10 times
Laser scattering for Sensing Surface DamageLaser scattering for Sensing Surface Damage
AFTER IGC ATTACKAFTER IGC ATTACKAS POLISHEDAS POLISHED
0 20 40 60 800.0
0.2
0.4
0.6
0.8
1.0
E tching tim e, sec
Specular reflection, Arb. units
0 20 40 60 80
0.8
0.9
0.4
0.5
0.6
0.7
Etching time, sec
FWHM (X 10mm)
1.0
Evaluation of Intergranular Corrosion in SSEvaluation of Intergranular Corrosion in SS
Most of the Damage Mechanisms initiate from the sur facesMost of the Damage Mechanisms initiate from the sur faces
23Pitting CorrosionPitting Corrosion Effect of etching time on IGC in SS Effect of etching time on IGC in SS
20 s20 s 80 s80 s
20 s20 s 80 s80 s
Intergranular corrosion detection in Waste tanks by ECIntergranular corrosion detection in Waste tanks by EC--GMR sensorGMR sensor
ExciterExciter –– Eddy current coil, Eddy current coil,
ReceiverReceiver: GMR sensor: GMR sensor
Giant magneto-resistive (GMR) effect is large change in res istance of nano layers due to appliedmagnetic field as a result of spin dependent scattering of el ectrons. In order to pick-up feeblemagnetic fields produced by eddy currents (EC) at sub-surfa ce corroded regions, GMRsensor has been integrated with eddy current coil. GMR sensi tivity: 10 nano Tesla
EC coilEC coil
GMR chipGMR chip
Corroded
Un-C
orroded
4mm
7mm
4 5 6 7 8 90 .00
0 .05
0 .10
0 .15
0 .20
0 .25
0 .30
0 .35
0 .40
0 .45
0 .50
Sen
sor
Out
put D
iffer
ence
, mv
D ep th b e lo w S u rfa ce , m m
E C -G M R respo nse 0.5 h r 1 h r 2 h rs
E C respo nse 0.5 h r 1 h r 2 h rs
EC-GMR sensor is capable to detect corrosion 9 mm below the surface
SuccessfulSuccessful applicationapplication forfor detectiondetection ofof internalinternal corrosioncorrosion inin 1212 mmmm thickthick 304304 LLwastewaste vaultvault tanktank byby scanningscanning fromfrom outerouter surfacesurface –– ISIISI tooltool withwith roboticsrobotics ..
GMRGMR 9mm
12mm thick AISI type 304L plate (Oxalic acid attack) EC-GMR Images
Corrosion an Inherent Problem-Solution through Inno vative Approach with Advanced NDE
Phase Image - Lock in Thermography
Quantitative Estimation
of
Corrosion in Structural
Elements
Two Novel and Complementary
Techniques
Robust
Life Phase Image - Lock in Thermography
Compton Back Scattering
Asset History
Environmental Details
Modelling
Risk Management
Life
Prediction
for
Structural
Longevity
Potential techniques for one sided inspection Potential techniques for one sided inspection suitable for large structures. Can give quantitati ve suitable for large structures. Can give quantitati ve
estimation of corrosion and also detect rebar estimation of corrosion and also detect rebar corrosion corrosion
Monte Carlo Numerical PredictionMonte Carlo Numerical Prediction
0.2950
0.2975
0.3000
0.3025
0.3050
0.3075
0.3100
0.3125
0.3150
0.3175
0.3200
0.3225For the Inconel 625 wrought cracker tubes at HWP, Thal and HWP, Tuticorin in various thermal exposure conditions
Poi
sson
's r
atio
Virgin (Thal) RSA (Thal) V+747 h (Tuti) RSA+23000 h (Thal) V+57194 h (Tuti) Failed in 1982 (Tuti) MC (~20000h) (Tuti) 120000 h (1-35, Thal)
�Ultrasonic measurements can be used to monitor the degradation in mechanical properties
−
−=
12
2
2
2
2
2
L
S
L
S
TOF
TOF
TOF
TOF
ν
Accuracy ~ ±±±± 0.0006
Service exposed (SE) : NH3cracker tube at ~873 K
1 hr and 600 hrs
120 140 160 180 200 220 240 260 280 300 320 340 360 3800.2925
0.2950
Hardness, VHN
120000 h (1-35, Thal) 120000 h (36-70, Thal)
Variation in Poisson’s ratio with hardness for cracker tubes in different service exposed conditions at heavy water plants at Thal and Tuticorin. (V-Virgin, MC-Mini Cracker, RSA-Re-solution annealed)
�Life span of these tubes for resolution annealing should not be based on merely the service duration, but on some practically measurable parameter, such as Poisson’s ratio and hardness
�Assessment of rejuvenation heat treatment of the tubes using ultrasonic measurements
Reused after rejuvenation by resolution annealing (RSA)
Magnetic Flux Leakage (MFL) ImagingMagnetic Flux Leakage (MFL) Imaging
YokeYoke
Carbon steel plateCarbon steel plate
ScannerScanner
GMR SensorGMR Sensor
MFLMFL imageimage ofof aa notchnotch locatedlocated atat66..22 mmmm belowbelow surfacesurface inin aa 1212 mmmm
MFL images of defects are obtained by MFL images of defects are obtained by scanning Giant Magnetoscanning Giant Magneto --Resistive (GMR) Resistive (GMR) 66..22 mmmm belowbelow surfacesurface inin aa 1212 mmmm
thickthick carboncarbon steelsteel plateplate
AA flexibleflexible arrayarray ofof eighteight GMRGMR sensorssensors developeddevelopedforfor automaticautomatic fastfast detectiondetection ofof flawsflaws andand lossloss ofofmetallicmetallic areaarea (LMA)(LMA) inin multimulti--strandstrand steelsteel wirewire ropesropes
scanning Giant Magnetoscanning Giant Magneto --Resistive (GMR) Resistive (GMR) sensor in a raster manner over the object.sensor in a raster manner over the object.
Array of 8 GMR sensorsArray of 8 GMR sensors
Scan Scan directiondirection
ResponseResponse ofof GMRGMR arrayarraysensorsensor toto sawsaw cutscuts inin 6464 mmmmdiameterdiameter wirewire roperope
5 saw cuts 5 saw cuts
Wire rope of HWP, ManuguruWire rope of HWP, Manuguru
Structured Approach to Asset ManagementStructured Approach to Asset Management
Asset Management
Design Objectives
Materials and Asset ManagementMaterials and Pre-service Data(Fabrication,
Machining,Welding
Qualification, etc)
Repairs and In-service Data
International Experiences
Asset and Knowledge Base essential for plants Asset and Knowledge Base essential for plants intended to serve for more than 40 years. The intended to serve for more than 40 years. The knowledge base is designed to serve as an expert knowledge base is designed to serve as an expert system for bigger plants. system for bigger plants.
Asset and Knowledge Management System (AsKMe)
Archives more than 40,000 documents,
records and drawings pertaining to
Demonstration Fuel Reprocessing Plant.
Unique features that distinguish it from
conventional database
Radiographic archive with user defined
(based on experience) software for
image analysis and measurements
Provision for Ultrasonic signals andProvision for Ultrasonic signals and
images with analysis
Knowledge capsule _ Interviews with
senior/retired project colleagues on field
problems and their innovative solutions.
Quality Circle problems and solutions
First of its kind attempt in DAE and
internationally. Appreciated by
Regulators.
Implementation of Six Sigma
Study envisaged the application of six sigma in the fabrication of complex and high density piping. 35,000 weld joints.
12,000 studied.
� Main types of defects that arise could be identified.
� Root causes of the defect could be ascertained to prevent in future pipings.pipings.
�R & D initiated – for example oxidation occurs because of lack of purging gas.
�Feasibility studies on using Flux cored / covered TIG welding filler wires to completely eliminate the purging.
�Trial implementation made in complex piping.
�100 % oxidation free joints achieved.
VALIDATEDDESIGN
FOCUSSEDINTER-
DISCIPLINARYRESEARCH PROVEN
MANUFACTURING TECHNOLOGIES
ROBUST
SUCCESSFUL LIFE CYCLE SUCCESSFUL LIFE CYCLE PERFORMANCE REQUIRE…PERFORMANCE REQUIRE…
INNOVATIVEINNOVATIVE APPROACHES,APPROACHES, SEAMLESSSEAMLESSINTEGRATIONINTEGRATION OFOF DISCIPLINESDISCIPLINES ANDANDENABLINGENABLING TECHNOLOGIESTECHNOLOGIES INTEGRATEDASSET AND KNOWLEDGE MANAGEMENT
RELIABLESENSORS,SYSTEMS
SAFE OPERATION
PROCEDURES
SYSTEMATIC, PLANNED ISI,
LIFE ASSESSMENT
ROBUST INSPECTION
and TQM
ASSET AND KNOWLEDGE MANAGEMENT
Approach for Implementing Innovations
• Critically review the internationally evolving designs and failure experiences
• Detail out the prospective options for future SFRs• Involve Industries to design and manufacture innovative
concepts • Academic institutes for design optimisation by analysis
• Recognising priorities, breakthrough areas by experts, young students and research scholars at the core of innovation
• Innovations eco-system with intertwining of young, senior, academic, research and industry
• Quality and motivated human resources with enabling networks and management ethics is a key to the safety of SFR
• Academic institutes for design optimisation by analysis• Testing in air at Industries and testing in sodium at IGCAR
Challenges : Miniature IR sensors, thermal noise, feature detection and identification Challenges : Miniature IR sensors, thermal noise, feature detection and identification –– robust robust fuzzy logic based systemsfuzzy logic based systems
RE
SID
UA
L S
TR
ES
S, M
Pa
-200
-300
-100
100
0
RE
SID
UA
L S
TR
ES
S, M
Pa
-300
-100
-200
0
XRD based Residual Stress Measurements for Life Assessment of Undercarriages of Fighter Aircrafts
NUMBER OF LANDINGS
-6000
RE
SID
UA
L S
TR
ES
S, M
Pa
-400
-500
-300
800400
1200
RE
SID
UA
L S
TR
ES
S, M
Pa
-6000
-400
-500
300DEPTH IN MICRONS
100 200
In collaboration with IAF & HAL, Nasik
The variation in residual stress in the depth direction
Number of Landings = 1050
Surface residual stress
The variation in surface residual stress in landing gears experienced different number of landings
Stresses,
microstructures,
micro and macro
defects through
X-ray diffraction for life
assessment of landing gears of
MIG-21
Micropores,
impact
damage, fibre
breakage in
composites
through
Remnant
core in
turbine -
K
7-FRONT
8-REAR
5-FRONT
6-REAR
3-FRONT
4-REAR
9
10
VIEW -K
2
1
REGIONS OF RESIDUAL
MAIN LANDING GEAR STRUT
STRESS MEASUREMENTS
MIG-21/23
Radiation based NDE
at IGCAR
through
micro focal
NDE
Inclusions, Glue variations,
Quality Assurance of assemblies
–
Conventional X-ray
turbine -
through
Neutron
Radiography-
KAMINI
Mi-8/17LCA
The simulation paradigmThe simulation paradigm
From: From: KuivanenKuivanen, ‘e, ‘e--Engineering (Digital Manufacturing)’Engineering (Digital Manufacturing)’, , VTT (Technical Research Centre of Finland), VTT (Technical Research Centre of Finland), 2010.2010.
www.monash.eduwww.monash.edu
Courtesy,
CSIRO, Australia
Courtesy,
CSIRO, Australia
Factors Affecting Measurements in NDEFactors Affecting Measurements in NDE
Material Material PropertiesProperties
Measurements Measurements in NDEin NDE
Sensor Sensor characteristicscharacteristics
Operator Operator qualification qualification and trainingand training
AutomationAutomation
Fixed Factors Fixed Factors Variable FactorsVariable Factors
Automation Automation
+ +
Defect Detection based on large defect database Defect Detection based on large defect database
+ +
Heuristic Knowledge of Experienced OperatorsHeuristic Knowledge of Experienced Operators
Inherent Noise Inherent Noise from sensor from sensor
and electronicsand electronics
Image and Image and Signal Signal
ProcessingProcessing
Six SigmaSix SigmaAsset & Knowledge Asset & Knowledge ManagementManagement
Indicates significanceIndicates significance
Analysis
Code
Model
Interactions
Materials
Microstructure
Production
Technology development
Modelling and Simulation
Sensors and NDT
Quality Assurance
Performance evaluation
Operator
Integration
Simulation
Software
ISI
NDE and Sensors
Review
Analysis
POD
Criteria
PERFORMANCE OF HIGH TECHNOLOGY PERFORMANCE OF HIGH TECHNOLOGY
COMPONENTS AND SYSTEMS COMPONENTS AND SYSTEMS -- MATURITY MAPPING MATURITY MAPPING
Microstructure
Composition
AssuranceHardware
Criteria
DesignManufacturing Technologies
Operation and maintenance
Health Monitoring
�� Excellence in Individual DomainsExcellence in Individual Domains
�� Fractured LinkagesFractured Linkages
�� Barriers of Disciplines and ManagementBarriers of Disciplines and Management
�� Lack of Integrated and holistic approachesLack of Integrated and holistic approaches
Challenging engineering and technological problems need…
Robust Measurements
Sensors
Electronics
Statistics
Sciences
Systems
Robust Analysis Clear Convincing even to concerned +
Galileo
Robust Analysis even to concerned non-specialists
+
Challenger Failure – Successful and Well Appreciated Solution based upon
Holistic Analysis with robust measurements and clear convincing
Richard Feynman
My Perspective of Missing Links …..� Measurements crucial for successful performance
Robust &
Quality &
Safety in Life
Health
High
Performance
System
How well have we understood and translated …How well have we understood and translated …
Relevant
Measurements
EnvironmentCultural Heritage
Health System
AVALANCHE
I
Acoustic Simulation of
PE-16 (µm size
precipitates) – Ph D
Thesis IzfP Germany
Kaiga Ring beam using
acoustic impact echo testing
Small innovative ideas triggering research and application spanning disciplines and organisations
Acoustic amplification based tests
for dislocation studies (µm-nm)
INNOVATIONS
Acoustic study of Humpy
musical pillars
Ca Oxalate kidney stone
acoustic microscopy
(10 nm thick layers)
AE energy / load vs.
normalized time
curve
Damage Micro-mechanisms in
Near Alpha Titanium Alloy
Defence Lab (DMRL)
Understanding Movement of
Dislocations with Acoustics
Ethical & Sustainable modelEthical & Sustainable model