Nondestructive Evaluation 4.0

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Nondestructive Evaluation 4.0(NDE 4.0) has been defined by Vrana et al. [1] as "the concept of cyber-physical non-destructive evaluation (including nondestructive testing) arising from Industry 4.0 digital technologies, [2] [3] [4] physical inspection methods, and business models. [5] It seeks to enhance inspection performance, integrity engineering and decision making for safety, sustainability, [6] and quality assurance, as well as provide timely and relevant data to improve design, production, and maintenance characteristics."

Contents

NDE 4.0 arose in response to the emergence of the Fourth Industrial Revolution, which can be traced to the development of a high-tech strategy for the German government in 2015, under the term Industrie 4.0. [7] The term became widely known in 2016 following its adoption as the theme of the World Economic Forum annual meeting in Davos. [8]

The concept gained strength following the opening of the Center for the Fourth Industrial Revolution in 2016 in San Francisco. [9] NDE 4.0 evolved in conjunction with Industry 4.0. [10] It is recognized as a future goal by several global NDE organizations: the International Committee for Nondestructive Testing (ICNDT) [11] has a Specialist international Group (SIG) on NDE 4.0, [12] and the European Federation for Nondestructive Testing (EFNDT) [13] created a working group designated as "EFNDT Working Group 10: NDE 4.0" (WG10). [14] The importance of NDE 4.0 is reflected in the activities of NDE organizations throughout the world, including the American Society of Nondestructive Testing (ASNT), [15] the British Institute of Non-Destructive Testing (BINDT), [16] and the German Society for Non-Destructive Testing (DGZfP), [17] through publications and training.

History

Visualization of the four industrial and NDE revolutions. For the definition of the four NDE revolutions it was chosen to define them independent from Industry by the revolutionary changes within NDE. The four industrial and NDE revolutions.svg
Visualization of the four industrial and NDE revolutions. For the definition of the four NDE revolutions it was chosen to define them independent from Industry by the revolutionary changes within NDE.

Leading to NDE 4.0, just as those leading to Industry 4.0 were prior developments that are divided into prior revolutions based on distinct technological and historical markers. These are usually defined for industry and hence for nondestructive evaluation.

NDE 1.0

The first revolution in nondestructive evaluation coincides with the first industrial revolution and refers to the period between approximately 1770 (following the invention of the Watt’s steam engine in 1769) and 1870. The transition from hand and artisanal production and “muscle power” to mechanized production and steam- and hydro-power necessitated the introduction of nondestructive testing. Prior to this period, people have tested objects for thousands of years through simple methods based human sensory perception – feeling, smelling listening and observing as appropriate.

The development in the first industrial revolution gave birth to non-destructive inspection through the introduction of tools that sharpened the human senses, and through tentative attempts at standardized procedures. Simple tools such as lenses, stethoscopes, tap and listen procedures and others, improved detection capabilities by enhancing human senses. Establishing procedures, made the outcome of the inspection comparable over time. At the same time, industrialization also made it necessary to expand quality assurance measures, a process that continues to this day.

NDE 2.0

The second revolution in NDE is commonly referred to as the period between 1870, with the appearance of first means of mass production, marked by the introduction of the conveyor belt, [19] and 1969. As with the second revolution in industry, it is characterized by use of physical, chemical, mechanical and electrical knowledge to improve testing and evaluation.

The transformation of electromagnetic and acoustic waves, which lie outside the range of human perception, into signals that can be interpreted by humans, resulted in means of interrogating components for better visualization of material inhomogeneities at or close to the surface. Following the discovery of X-rays in 1895, it became a dominant method for testing, followed by gamma-ray testing and later, electromagnetic means of testing.

With the introduction of the transistor into electronics, testing methods such as ultrasound developed further into lighter, portable systems suitable for field testing. The first detectors for infrared and terahertz detection were invented around the same time and the first eddy current devices became available. Although these are critical methods of testing that persist to this day, further breakthroughs had to wait until digitization and digital electronics developed in the third NDE revolution.

NDE 3.0

The third revolution in NDE parallels the advent of microelectronics, digital technologies and computers. It is usually thought of as the period starting in 1969, marked by the introduction of the first programmable logic controller (PLC), [20] and 2016. Digital inspection equipment, such as X-ray detectors, digital ultrasonic and eddy current equipment, and digital cameras became integral parts of the system of testing and evaluation. Robotics lead to automated processes, improving convenience, safety, speed and repeatability.

Digital technologies offered leaps in managing inspection data acquisition, storage, processing, 2D and 3D imaging, interpretation, and communication. Data processing and sharing became the norm. At the same time, these developments created new challenges and opportunities such as data security and integrity and introduced new concepts such as value of data and its monetization.

NDE 4.0

Whereas prior revolutions focused on improving testing and evaluation by taking advantage of the tools, methods and development available at the respective periods, the 4th NDE revolution is characterized by integration; integration of tools, testing methods, digital technologies, and communication into coherent closed-loop systems that allows both feedback and feed-forward to manufacturing. The purpose is improvement in testing and evaluation taking advantage of current and emerging production technologies and communication and information systems.

At the heart of NDE 4.0 are digitalization, networking, information transparency, communication and processing tools such as artificial intelligence and machine learning. One of the primary added values in NDE 4.0 is the possibility of product design and concurrent nondestructive evaluation through use of digital twins and digital threads, so that both design and testing can influence each other continuously. Another is the ability to serve emerging trends such as testing in custom manufacturing, remote testing and predictive maintenance over the lifetime of products.

NDE 4.0 is not a fixed set of rules and concepts but rather and evolving progression of ideas, tools and procedures brought about by advances in production, communication and processing. Its global purpose is to serve the needs of industry and respond to changes brought about by emergence of new opportunities.

Drivers and components

The primary driver of NDE 4.0 is the same as that of the fourth industrial revolution – the integration of digital tools and physical methods, driven by current digital technologies through introduction of new ways of digitalization of specific steps in NDE processes, with a promise of overall efficiency and reliability. There are three recognizable components of NDE 4.0. First, Industry 4.0 emerging digital technologies can be used to enhance NDE capabilities in what has been termed  “Industry 4.0 for NDE”. Second, statistical analysis of NDE data provides insight into product performance and reliability. This is a valuable data source for Industry 4.0 to continuously improve the product design in the “NDE for Industry 4.0” process. [10] [18] Third, immersive training experiences, remote operation, intelligence augmentation, and data automation can enhance the NDE value proposition in terms of inspector safety and human performance in the third component of NDE 4.0 – the “Human Consideration”.

International Conference on NDE 4.0

The International Conference on NDE 4.0 was initiated by the ICNDT Specialist international Group (SIG) on NDE 4.0 and is planned to be organized bi-annually (this plan is currently altered due to the Corona Crises):

  1. 14/15 & 20/21 April 2021: Virtual Conference with 4 keynotes, 26 invited presentations and four panel discussions organized (video recordings available online) by DGZfP and co-sponsored by ICNDT [21]
  2. 24 – 27 October 2022 in Berlin, Germany with 4 keynotes and 15 technical sessions (including Artificial intelligence, Digital twin, Additive Manufacturing, Extended Reality, Reliability, and Predictive Maintenance). [22] This conference was organized by DGZfP and co-sponsored by ICNDT. At this conference the Kurzweil Award for High Impact in NDE 4.0 (named after Ray Kurzweil) was initiated and awarded to Prof. Dr. Norbert Meyendorf and Prof. Dr. Bernd Valeske for their work "Starting the Field of NDE 4.0". [23]
  3. February 2025 in India. This conference is organized by the Indian Society for Non-destructive Testing (ISNT) and co-sponsored by ICNDT. [23]

Further reading

Peer-reviewed publications on the topic of NDE 4.0 were covered in multiple special issues and books:

Related Research Articles

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<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">Inspection</span> Organized examination or formal evaluation exercise

An inspection is, most generally, an organized examination or formal evaluation exercise. In engineering activities inspection involves the measurements, tests, and gauges applied to certain characteristics in regard to an object or activity. The results are usually compared to specified requirements and standards for determining whether the item or activity is in line with these targets, often with a Standard Inspection Procedure in place to ensure consistent checking. Inspections are usually non-destructive.

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">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.

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<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."

<span class="mw-page-title-main">Industrial computed tomography</span> Computer-aided tomographic process

Industrial computed tomography (CT) scanning is any computer-aided tomographic process, usually X-ray computed tomography, that uses irradiation to produce three-dimensional internal and external representations of a scanned object. Industrial CT scanning has been used in many areas of industry for internal inspection of components. Some of the key uses for industrial CT scanning have been flaw detection, failure analysis, metrology, assembly analysis and reverse engineering applications. Just as in medical imaging, industrial imaging includes both nontomographic radiography and computed tomographic radiography.

The American Society for Nondestructive Testing, Inc. or ASNT is a technical society for nondestructive testing (NDT) professionals. ASNT evolved from The American Industrial Radium and X-ray Society which was founded in 1941. Its headquarters is located in Columbus, Ohio, and there are 70 local sections in the United States and 14 local sections in other countries.

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.

Vidisco is an Israeli based developer and manufacturer of portable digital X-ray inspection systems.

<span class="mw-page-title-main">TeraView</span>

TeraView Limited, or TeraView, is a company that designs terahertz imaging and spectroscopy instruments and equipment for measurement and evaluation of pharmaceutical tablets, nanomaterials, ceramics and composites, integrated circuit chips and more.

<span class="mw-page-title-main">Fourth Industrial Revolution</span> Current trend, manufacturing technology

"Fourth Industrial Revolution", "4IR", or "Industry 4.0" is a buzzword neologism describing rapid technological advancement in the 21st century. The term was popularised in 2016 by Klaus Schwab, the World Economic Forum founder and executive chairman, who says that the changes show a significant shift in industrial capitalism.

<span class="mw-page-title-main">James H. Williams Jr.</span>

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Microwave imaging is a science which has been evolved from older detecting/locating techniques in order to evaluate hidden or embedded objects in a structure using electromagnetic (EM) waves in microwave regime. Engineering and application oriented microwave imaging for non-destructive testing is called microwave testing, see below.

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.

The Hale Interchange is the major interchange between Interstate 41 (I-41), I-43, I-894, US Highway 41 (US 41), and US 45 in the Milwaukee, Wisconsin, southwest suburb of Greenfield, though it takes it name from the nearby community of Hales Corners.

<span class="mw-page-title-main">Laszlo Adler</span> American physicist

Laszlo Adler is an American physicist and a Taine McDougal Professor Emeritus in the Department of Integrated Systems Engineering at the Ohio State University. He is known for his work in Ultrasonics, Acousto-optics, and Nondestructive Evaluation of Materials. He is a holocaust survivor and has been active in scientific research for over 60 years.

References

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