Infrared non-destructive testing of materials

Last updated

Active thermography is an advanced nondestructive testing procedure, which uses a thermography measurement of a tested material thermal response after its external excitation. This principle can be used also for non-contact infrared non-destructive testing (IRNDT) of materials.

Contents

The IRNDT [1] method is based on an excitation of a tested material by an external source, which brings some energy to the material. Halogen lamps, flash-lamps, ultrasonic horn or other sources can be used as the excitation source for the IRNDT. The excitation causes a tested material thermal response, which is measured by an infrared camera. It is possible to obtain information about the tested material surface and sub-surface defects or material inhomogeneities by using a suitable combination of excitation source, excitation procedure, infrared camera and evaluation method.

Modern thermographic systems with high-speed and high-sensitivity IR cameras extend the possibilities of the inspection method. Modularity of the systems allows their usage for research and development applications as well as in modern industrial production lines.

Thermovision nondestructive testing of components can be carried out on a wide range of various materials. Thermographic inspection of material can be regarded as a method of infrared defectoscopy, that is capable of revealing material imperfections such as cracks, defects, voids, cavities and other inhomogeneities. The thermographic testing can be provided on individual components in a laboratory or directly on technology facilities that are in duty.

Introduction to infrared thermography

Infrared (IR) thermography [2] is an analysis technique based on the detection of radiation in the IR part of the electromagnetic spectrum. According to the black body radiation law, all objects with temperature greater than absolute zero emit IR radiation. The device detecting and composing a 2D image of the IR radiation is generally called an IR camera or a thermographic camera, also referred to as an infrared camera. The result of the thermographic recording is an image or a sequence, which corresponds to the intensity of the thermal radiation of the recorded object. The recording is called a thermogram. The intensity of the thermal radiation of the object is directly connected with the object temperature. The thermogram is therefore an image of the object surface temperature distribution. IR thermography is in the most cases used for non-contact measurement of spatial and time distribution of temperature fields.

Scheme of the principles and factors influencing a thermographic measurement. IRNDT fig 01 en.png
Scheme of the principles and factors influencing a thermographic measurement.

Properties

IR thermography has a number of advantages – it is non-contact measurement, it captures an area (similarly to the classical video camera in visible spectrum) or it can measure moving or rotating objects, even if the objects have a very high temperature. However, the IR radiation intensity detected by the infrared camera does not depend solely on the measured object temperature.

The main drawback of IR thermography is the fact that the result is influenced by a number of factors such as the thermo-optical properties of the object (emissivity, transmissivity, reflectivity), [3] ambient temperature, environment properties, etc. Especially the knowledge of the measured object optical properties are fundamental for an accurate temperature measurement. Determination of these properties is often a complicated task and it requires both experience and the appropriate equipment.

Classification

Thermography can be classified as qualitative or quantitative, and passive or active. Qualitative thermography usually does not require an accurate temperature measurement. It only evaluates temperature differences between particular components, between different spots on the same object or between the measured object and the background. Qualitative thermography has many important applications, for example a thermal leaks diagnostics, thermal components diagnostics, searching for persons or in medicine. In contrast, the goal of quantitative thermography is an accurate temperature measurement of inspected objects. Knowledge of thermo-optical properties of the measured objects is essential in this case. Moreover, the thermo-optical properties often depend on temperature and it is also necessary to take into account an influence of environment.

Important applications of quantitative thermography include temperature monitoring during thermal processing or determination of thermal boundary conditions for numerical simulations of thermal processes.

Both the qualitative and quantitative approaches can be applied in terms of passive or active thermography. If the object temperature is not artificially affected during its measuring, it is called the passive thermography. If an artificial excitation using an external source is applied on the measured object, it is called active thermography. The external excitation causes temperature contrasts associated with material inhomogeneities or defects occurrence or it can be used for material properties identification. The active thermography is the important technique used for finding defects in materials, so called infrared non-destructive testing (IRNDT). Active thermography can be also applied for material thermal properties determination.

Infrared non-destructive testing (IRNDT)

Active thermography

Scheme of the active thermography principle. IRNDT fig 02 en.png
Scheme of the active thermography principle.

Active thermography uses an external source for measured object excitation, that means introducing an energy into the object. The excitation sources can be classified by the principles:

Various excitation sources can be used for the active thermography and nondestructive testing, for example laser heating, flash lamps, halogen lamps, electrical heating, ultrasonic horn, eddy currents, microwaves, and others. The measured object can be heated by an external source directly, e.g. by halogen lamps or hot air. The material inhomogeneities or defects cause then a distortion of temperature field. This distortion is detected as temperature differences on the material surface. Another possibility is to use thermophysical processes in the material, when mechanical or electrical energy is transformed into thermal energy due to defects and inhomogeneities. It creates local temperature sources, which cause temperature differences detected on the object surface by infrared techniques. It is the case of ultrasound excitation for example.

IRNDT methods

A lot of methods were developed for active thermography for the nondestructive testing measurement evaluation. The evaluation methods selection depends on application, used excitation source and excitation type (pulse, periodic, continuous). In the simplest case, the response is evident from a thermogram directly. However, it is necessary to use advanced analysis techniques in most cases. The most common methods include Lock-In, Pulse or Transient (Step thermography) evaluation techniques. Continuous excitation can also be used in some cases.

A high-speed cooled infrared camera with a high sensitivity is commonly used for IRNDT applications. However, an uncooled bolometric infrared camera can be used for specific applications. It can significantly reduce acquisition costs of the measurement system.

The IR nondestructive testing system are usually modular. It means that various excitation sources can be combined with various infrared cameras and various evaluation methods depending on application, tested material, measuring time demands, size of a tested area, etc. The modularity allows universal usage of the system for various industrial, scientific and research applications.

Application examples

IRNDT (infra-red nondestructive testing) method is suitable for detection and inspection of cracks, defects, cavities, voids and inhomogeneities in material, it is also possible to use the method for inspection of welded joints of metal and plastic parts, inspection of solar cells and solar panels, determination of internal structure of material etc.

The main advantage of IRNDT method is availability for inspection of various materials in wide range of industrial and research applications. IRNDT measurement is fast, nondestructive and noncontact. Restrictive condition for IRNDT method is inspection depth combined with dimension and orientation of defect/crack/inhomogeneity in material.

Pulse IRNDT analysis of a demonstration sample

Demonstration of tested specimen and IRNDT analysis results. IRNDT fig 03 en.jpg
Demonstration of tested specimen and IRNDT analysis results.

The demonstration and calibration sample is made of carbon fiber-epoxy composite. There are six holes of different depths on one side to simulate defects at different depths in range from 1 to 4 mm under the surface. The IRNDT analysis is performed from the flat side.

The results from the flash-pulse analysis show that the holes appear in different time frames of the evaluation – according to their depth. So the flash-pulse analysis does not only detect the presence of defects but also determine their depth under the surface if a thermal diffusivity of the sample is known.

Inspection of laser welded plastic parts

IRNDT analysis of laser welded plastic part with a defective weld and with a correct weld. IRNDT fig 04 en.jpg
IRNDT analysis of laser welded plastic part with a defective weld and with a correct weld.

Laser welding of plastics is a progressive technology of connecting materials with different optical properties. Classical methods for testing of welding performance and weld joints quality – such as the metallographic cut microscopic analysis or X-ray tomography – are not suitable for routine measurements. Pulse IRNDT analysis can be successfully used for weld inspection in many cases.

The images show an example of plastic parts inspection with a defective weld and with a correct weld. The gaps in the defective weld and the correct uninterrupted weld line are both well visible in the results of the IRNDT flash-pulse analysis.

Inspection of laser welded joints

IRNDT evaluation with an indication of weld imperfections and a correct weld of lap joint. IRNDT fig 05 en.jpg
IRNDT evaluation with an indication of weld imperfections and a correct weld of lap joint.

Laser beam welding is a modern technology of fusion welding. Currently finds its wide usage not only in the field of scientific research but also establishes itself in a variety of industries. Among the most frequent users belong the automotive industry, which due to its stable continuous innovation enables fast implementation of advanced technologies in their production. It is clear that laser welding significantly enhances engineering designs and thus brings a number of new products which previously could not be made by conventional methods.

The laser welding can produce quality welds of different types, both extremely thin and thick blanks. Weldable are common carbon steels, stainless steels, aluminum and its alloys, copper, titanium and last but not least, special materials and its combinations.

An integral part of the weldments production is a quality control. Unlike conventional non-destructive test methods, IRNDT is used not only after the laser welding process, but also during it. This makes possible to decide whether or not to the weldment comply with established quality criteria during manufacture process.

Related Research Articles

<span class="mw-page-title-main">Infrared</span> Form of electromagnetic radiation

Infrared is electromagnetic radiation (EMR) with wavelengths longer than those of visible light and shorter than radio waves. It is therefore invisible to the human eye. IR is generally understood to encompass wavelengths from around 1 millimeter (300 GHz) to the nominal red edge of the visible spectrum, around 700 nanometers (430 THz). IR is commonly divided between longer wavelength thermal infrared that is emitted from terrestrial sources and shorter wavelength near-infrared that is part of the solar spectrum. Longer IR wavelengths are sometimes included as part of the terahertz radiation range. Almost all black-body radiation from objects near room temperature is at infrared wavelengths. As a form of electromagnetic radiation, IR propagates energy and momentum, exerts radiation pressure, and has properties corresponding to both those of a wave and of a particle, the photon.

<span class="mw-page-title-main">Thermographic camera</span> Imaging device using infrared radiation

A thermographic camera is a device that creates an image using infrared (IR) radiation, similar to a normal camera that forms an image using visible light. Instead of the 400–700 nanometre (nm) range of the visible light camera, infrared cameras are sensitive to wavelengths from about 1,000 nm to about 14,000 nm (14 μm). The practice of capturing and analyzing the data they provide is called thermography.

<span class="mw-page-title-main">Nondestructive testing</span> Evaluating the properties of a material, component, or system without causing damage

Nondestructive testing (NDT) is any of a wide group of analysis techniques used in science and technology industry to evaluate the properties of a material, component or system without causing damage. The terms nondestructive examination (NDE), nondestructive inspection (NDI), and nondestructive evaluation (NDE) are also commonly used to describe this technology. Because NDT does not permanently alter the article being inspected, it is a highly valuable technique that can save both money and time in product evaluation, troubleshooting, and research. The six most frequently used NDT methods are eddy-current, magnetic-particle, liquid penetrant, radiographic, ultrasonic, and visual testing. NDT is commonly used in forensic engineering, mechanical engineering, petroleum engineering, electrical engineering, civil engineering, systems engineering, aeronautical engineering, medicine, and art. Innovations in the field of nondestructive testing have had a profound impact on medical imaging, including on echocardiography, medical ultrasonography, and digital radiography.

<span class="mw-page-title-main">Thermography</span> Use of thermograms to study heat distribution in structures or regions

Infrared thermography (IRT), thermal video and/or thermal imaging, is a process where a thermal camera captures and creates an image of an object by using infrared radiation emitted from the object in a process, which are examples of infrared imaging science. Thermographic cameras usually detect radiation in the long-infrared range of the electromagnetic spectrum and produce images of that radiation, called thermograms. Since infrared radiation is emitted by all objects with a temperature above absolute zero according to the black body radiation law, thermography makes it possible to see one's environment with or without visible illumination. The amount of radiation emitted by an object increases with temperature; therefore, thermography allows one to see variations in temperature. When viewed through a thermal imaging camera, warm objects stand out well against cooler backgrounds; humans and other warm-blooded animals become easily visible against the environment, day or night. As a result, thermography is particularly useful to the military and other users of surveillance cameras.

<span class="mw-page-title-main">Plastic welding</span> Welding of semi-finished plastic materials

Plastic welding is welding for semi-finished plastic materials, and is described in ISO 472 as a process of uniting softened surfaces of materials, generally with the aid of heat. Welding of thermoplastics is accomplished in three sequential stages, namely surface preparation, application of heat and pressure, and cooling. Numerous welding methods have been developed for the joining of semi-finished plastic materials. Based on the mechanism of heat generation at the welding interface, welding methods for thermoplastics can be classified as external and internal heating methods, as shown in Fig 1.

<span class="mw-page-title-main">Transparent ceramics</span> Ceramic materials that are optically transparent

Many ceramic materials, both glassy and crystalline, have found use as optically transparent materials in various forms from bulk solid-state components to high surface area forms such as thin films, coatings, and fibers. Such devices have found widespread use for various applications in the electro-optical field including: optical fibers for guided lightwave transmission, optical switches, laser amplifiers and lenses, hosts for solid-state lasers and optical window materials for gas lasers, and infrared (IR) heat seeking devices for missile guidance systems and IR night vision.

Phosphor thermometry is an optical method for surface temperature measurement. The method exploits luminescence emitted by phosphor material. Phosphors are fine white or pastel-colored inorganic powders which may be stimulated by any of a variety of means to luminesce, i.e. emit light. Certain characteristics of the emitted light change with temperature, including brightness, color, and afterglow duration. The latter is most commonly used for temperature measurement.

Eddy-current testing is one of many electromagnetic testing methods used in nondestructive testing (NDT) making use of electromagnetic induction to detect and characterize surface and sub-surface flaws in conductive materials.

<span class="mw-page-title-main">Ultrasonic testing</span> Non-destructive material testing using ultrasonic waves

Ultrasonic testing (UT) is a family of non-destructive testing techniques based on the propagation of ultrasonic waves in the object or material tested. In most common UT applications, very short ultrasonic pulse-waves with center frequencies ranging from 0.1-15 MHz, and occasionally up to 50 MHz, are transmitted into materials to detect internal flaws or to characterize materials. A common example is ultrasonic thickness measurement, which tests the thickness of the test object, for example, to monitor pipework corrosion.

<span class="mw-page-title-main">Infrared thermometer</span> Thermometer which infers temperature by measuring infrared energy emission

An infrared thermometer is a thermometer which infers temperature from a portion of the thermal radiation sometimes called black-body radiation emitted by the object being measured. They are sometimes called laser thermometers as a laser is used to help aim the thermometer, or non-contact thermometers or temperature guns, to describe the device's ability to measure temperature from a distance. By knowing the amount of infrared energy emitted by the object and its emissivity, the object's temperature can often be determined within a certain range of its actual temperature. Infrared thermometers are a subset of devices known as "thermal radiation thermometers".

<span class="mw-page-title-main">Phased array ultrasonics</span> Testing method

Phased array ultrasonics (PA) is an advanced method of ultrasonic testing that has applications in medical imaging and industrial nondestructive testing. Common applications are to noninvasively examine the heart or to find flaws in manufactured materials such as welds. Single-element probes, known technically as monolithic probes, emit a beam in a fixed direction. To test or interrogate a large volume of material, a conventional probe must be physically scanned to sweep the beam through the area of interest. In contrast, the beam from a phased array probe can be focused and swept electronically without moving the probe. The beam is controllable because a phased array probe is made up of multiple small elements, each of which can be pulsed individually at a computer-calculated timing. The term phased refers to the timing, and the term array refers to the multiple elements. Phased array ultrasonic testing is based on principles of wave physics, which also have applications in fields such as optics and electromagnetic antennae.

<span class="mw-page-title-main">Time-of-flight diffraction ultrasonics</span>

Time-of-flight diffraction (TOFD) method of ultrasonic testing is a sensitive and accurate method for the nondestructive testing of welds for defects. TOFD originated from tip diffraction techniques which were first published by Silk and Liddington in 1975 which paved the way for TOFD. Later works on this technique are given in a number of sources which include Harumi et al. (1989), Avioli et al. (1991), and Bray and Stanley (1997).

<span class="mw-page-title-main">Non-contact thermography</span>

Non-contact thermography, thermographic imaging, or medical thermology is the field of thermography that uses infrared images of the human skin to assist in the diagnosis and treatment of medical conditions. Medical thermology is sometimes referred to as medical infrared imaging or tele-thermology and utilizes thermographic cameras. According to the American Academy of Thermology, Medical Thermology practitioners are licensed health care practitioners who utilize IR imaging in consistent with medically established paradigms of care. Non-medically licensed alternative practitioners who are not held to the same standard may offer thermography services but that should not be confused with the field of medical thermology.

Thermographic inspection refers to the nondestructive testing (NDT) of parts, materials or systems through the imaging of the temperature fields, gradients and/or patterns ("thermograms") at the object's surface. It is distinguished from medical thermography by the subjects being examined: thermographic inspection generally examines inanimate objects, while medical thermography generally examines living organisms. Generally, thermographic inspection is performed using an infrared sensor.

Infrared vision is the capability of biological or artificial systems to detect infrared radiation. The terms thermal vision and thermal imaging, are also commonly used in this context since infrared emissions from a body are directly related to their temperature: hotter objects emit more energy in the infrared spectrum than colder ones.

<span class="mw-page-title-main">Infrared and thermal testing</span>

Infrared and thermal testing refer to passive thermographic inspection techniques, a class of nondestructive testing designated by the American Society for Nondestructive Testing (ASNT). Infrared thermography is the science of measuring and mapping surface temperatures.

"Infrared thermography, a nondestructive, remote sensing technique, has proved to be an effective, convenient, and economical method of testing concrete. It can detect internal voids, delaminations, and cracks in concrete structures such as bridge decks, highway pavements, garage floors, parking lot pavements, and building walls. As a testing technique, some of its most important qualities are that (1) it is accurate; (2) it is repeatable; (3) it need not inconvenience the public; and (4) it is economical."

Maintenance of today's bridge infrastructure presents many challenges. Transportation engineering and maintenance personnel must maintain around the clock service to millions of people each year while maintaining millions of cubic meters of concrete distributed throughout their facilities. This infrastructure includes bridges. Presently only a limited number of accurate and economical techniques exist to test these structures for integrity and safety as well as insure that they meet original design specifications.

Terahertz nondestructive evaluation pertains to devices, and techniques of analysis occurring in the terahertz domain of electromagnetic radiation. These devices and techniques evaluate the properties of a material, component or system without causing damage.

Welding of advanced thermoplastic composites is a beneficial method of joining these materials compared to mechanical fastening and adhesive bonding. Mechanical fastening requires intense labor, and creates stress concentrations, while adhesive bonding requires extensive surface preparation, and long curing cycles. Welding these materials is a cost-effective method of joining concerning preparation and execution, and these materials retain their properties upon cooling, so no post processing is necessary. These materials are widely used in the aerospace industry to reduce weight of a part while keeping strength.

<span class="mw-page-title-main">Photovoltaic module analysis techniques</span>

Multiple different photovoltaic module analysis techniques are available and necessary for the inspection of photovoltaic (PV) modules, the detection of occurring degradation and the analysis of cell properties.

References