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Alternating current field measurement (ACFM) is an electromagnetic technique used for the detection and
sizing of surface breaking cracks in metallic components and welds. It combines the advantages of the
alternating current potential drop (ACPD) technique and Eddy Current Testing (ECT) in terms of defect sizing
without calibration and ability to work without electrical contact respectively.
The ACFM probe introduces an electric current locally into the part and measures the associated
electromagnetic fields close to the surface. The presence of a defect disturbs the associated fields and the
information is graphically presented to the system operator. The ends of a defect are easily identified to
provide information on defect location and length. Through wall extent of the flaw plays an important role in
determining structural integrity and the same is calculated using mathematical computation thus allowing an
immediate evaluation of the implication of the indication. ACFM inspection can be performed through paint
and coatings, hence it is considered to be a faster and economic technique than others (E.g. magnetic
particle inspection (MPI).
TWI Resources
TWI owns the state-of-the-art Amigo ACFM system supplied by Technical Software Consultants (TSC)
accompanied by special probes. The induction coil typically operates at 5 kHz with standard probes and 50
KHz with special high-frequency probes. The 50 kHz high-frequency probes are typically used to obtain
higher test sensitivity for nonmagnetic conductive materials.
Benefits
Applicable for base material or welds, ferritic or non-ferritic conductive metals
Requires minimal surface preparation and can be applied over paint and other coatings
Applications
Inspection of gear box, gear teeth, crank shafts, cylinder heads, turbines etc. in aerospace industries
Detection of cracks and corrosion in vessels, storage tanks and piping in oil & gas and power
generation industries
Digital Radiography
Digital radiography is an advanced technology based on digital detector systems in which the x-ray image is
displayed directly on a computer screen without the need for developing chemicals or intermediate
scanning. The incident x-ray radiation is converted into an equivalent electric charge and then to a digital
image through a detector sensor. Compared to other imaging devices flat panel detector provides high
quality digital images with better signal to noise ratio and improved dynamic range, which in turn provides
high sensitivity for radiographic application.
Flat panel detectors work on two different approaches, namely indirect conversion and direct conversion.
Indirect conversion flat panel detectors utilize a photo diode matrix of amorphous silicon. Direct conversion
flat panel detectors use a photo conductor like amorphous selenium (a-Se) or Cadmium telluride (Cd-Te) on
a multi-micro electrode plate and provides the greatest sharpness and resolution. The information on both
types of detectors is read by thin film transistors.
In the direct conversion process, when photons impact over the photo conductor, like amorphous Selenium,
they are directly converted to electronic signals which are amplified and digitised. As there is no scintillator,
lateral spread of photons is absent here ensuring a sharper image. This differentiates it from indirect
construction.
TWI Resources
TWI has two digital x-ray systems: a 450kV broad focus system and a 225kV micro-focus system.
Benefits
Higher productivity
Portability
Applications
Aerospace product examination
Detection of Corrosion Under Insulation (CUI) in petrochemical, oil & gas and power generation
industries
An Appreciation of Advanced Radiography (CR, DR and CT) – 4 day training course covering: Computerised
Radiography (CR), Digital Radiography (DR) and Computerised Tomography (CT). Suitable for Radiographic
Testing Operators qualified to at least Level 1, in accordance with ISO 9712, engaged in radiographic
testing/interpretation who need to update their knowledge to incorporate digital radiography, and personnel
engaged in the supervision, control and interpretation of radiographic images who wish to expand their
knowledge to incorporate digital radiography.
Continuous wave eddy current testing is one of several non-destructive testing methods that use the
electromagnetism principle. Conventional eddy current testing utilises electromagnetic induction to detect
discontinuities in conductive materials.
A specially designed coil energised with alternating current is placed in proximity to the test surface
generating changing magnetic-field which interacts with the test-part producing eddy current in the vicinity.
Variations in the changing phases and magnitude of these eddy currents is then monitored through the use
of receiver-coil(s), or by measuring changes to the alternate current flowing in the primary excitation-coil.
The electrical conductivity variations or magnetic permeability of the test-part, or the presence of any
discontinuities, will cause a change in eddy current and a corresponding change in phases and amplitude of
the measured current. The changes are shown on a screen for easy interpretation.
Another method of using the eddy current principle is pulsed eddy current testing. Methods are being
developed to investigate surfaces through protective coatings, weather sheetings, corrosion products and
even the insulation materials.
Inspection of surfaces at high temperature are possible with the eddy current technique as it is a non-
contact method.
TWI Resources
MultiView™ software
EtherNDE veritor single frequency laptop based system with automated controls
Techniques available with this type of testing are:
Benefits
Detection of very small cracks in or near the surface of the test part
No couplant is required
Applications
Full matrix capture (FMC) is a data acquisition strategy that allows for the capture of every possible
transmit-receive combination for a given ultrasonic phased array transducer.
Acquired data is processed in real-time using an optimised version of the total focusing method (TFM)
algorithm which generates fully focused images from the FMC data. This new technique aims to increase the
reliability of ultrasonic inspection, leading to reduced costs and improved safety for industry.
TWI has been researching and developing full matrix capture technology for a number of years, and it is
now at the stage where it is ready for industrial testing, validation and uptake.
High resolution
Real-time inspection
Ease of interpretation
Current technology
Real-time imaging through advanced software optimisation and parallelisation of the TFM algorithm
Calibration of inspection sensitivity allowing a uniform amplitude response throughout the region of
interest
Hybrid phased array/TFM technique for rapid inspection (100+ frames per second) using large arrays
Dynamic Link Library (.DLL) for integration into third-party software packages
Future technology
Self tandem capability for vertically aligned through-wall planar flaws in weld geometries
petrochemical industries for a method to detect corrosion under insulation in pipework and subsequently led
to creation of a wholly owned subsidiary Plant Integrity Ltd and the development of the first commercial
Guided wave technology is now widely accepted and used to inspect pipes in inaccessible areas such as road
and river crossings, power plant tubing, risers, offshore topside pipework, jetty lines and refinery pipework.
The success of Teletest meant that the system was bought as a business by Eddyfi Technologies in October
2017. TWI and Plant Integrity continues its work in the field with Members and customers on collaborative
and industrially sponsored projects.
Laser Shearography
Laser Shearography uses the coherent and monochromatic properties of laser light to illuminate the surface
of a component under investigation. If the surface is optically rough e.g. not a mirror surface, the lights
reflected by the component surface will generate a speckle pattern. This speckle pattern is then recorded
by a digital camera.
When the component is stressed e.g. by a mechanical load, thermal heating etc., the speckle pattern will
change accordingly as the component deforms. By recording the new speckle pattern, and subtracting it
from the original speckle pattern, a shearograpic fringe pattern will be produced and can be displayed on a
computer screen.
This fringe pattern contains information about the relative deformation of the component between its two
states (before and after stress), and is made up of a series of characteristic black and white
fringes. When there are no features within the component, a regular fringe pattern (usually in the form of
uniformly distributed fringes) will be obtained. When there is a subsurface feature such as a defect (e.g.
a void, crack, or delamination), or a stringer, the regular fringe pattern will be disturbed.
This enables the defect to be identified by the operator. In addition, the shearographic fringe pattern can
also be used to quantitatively measure the deformation of the component, rendering shearography a
powerful non-contact, full field strain/stress measurement technique.
TWI Resource
TWI owns a Laser Optical Engineering SM 1200 strain mapper. This is unique in that it can separately
resolve in-plane and out-of-plane strain through the use of a novel dual laser system. This is especially
useful when it is necessary to differentiate between faults that produce mainly out-of-plane strain, such as
skin to core disbonds, and those that produce mostly in-plane strain, such as cracks.
TWI has also established an optical lab, which contains two vibration isolated optical tables, a range of laser
sources (class 3B and class 4), several high definition digital cameras, and a high speed camera. A team is
dedicated to developing optical techniques for NDT and strain/displacement measurement, which includes
four Marie Curie Fellows since 2007.
Benefits
High sensitivity
Applications
Aerospace
Power generation
TWI has been developing laser-ultrasonic testing techniques for many years and is now able to provide
Laser ultrasonics is a cutting edge non-destructive testing (NDT) method in which lasers are used to
Laser-ultrasonic testing is able to remotely generate ultrasound in materials without contact, leaves a very
small footprint so that it can be applied to irregular geometries, and allows access to restricted areas via
fibre optics.
Our resources
IOS research kit including laser generator, laser receiver, ADC card, scanner and software
Generation laser with 9ns pulse duration
Non-contact and remote, allowing inspection of samples at high temperature, e.g. during welding with
restricted access
Industrial in-process measurements on hot, hazardous, remote samples which may be moving at high
speeds
TWI is pursuing various laser-ultrasonics projects involving the inspection of friction stir welds, laser
material depositing and composite materials
Intensive research on the mechanisms of generation and properties of the ultrasound produced has been
carried out since the 1980s. A technology readiness level of between six and eight has reached by certain
laser-ultrasonic applications, such as thickness measurement for steel tubes coming out from the mill and
damage detection of composite aircraft components.
TWI has carried out a number of research projects in developing laser-ultrasonic testing as an online
inspection tool for different welding processes and continues to investigate the technology’s potential.
Broadly speaking, the mechanisms of generating ultrasound using this method are laser thermal shock and
laser ablation. They both deposit a rapid laser pulse on the material surface, inducing a sudden stress in the
sample. The stress then propagates in the material as ultrasound. Broadband, multi-mode waves are
generated simultaneously.
Typically the UT inspection system consists of a transducer, pulser/receiver, and display unit. A
pulser/receiver is an electronic device that can produce high voltage electrical pulses to the transducer.
When driven by the pulser, the transducer generates high frequency ultrasonic sound energy into the
material in the form of sound waves.
When there are discontinuities such as inclusions, porosity, cracks, etc. in the sound path, part of the
mechanical energy will be reflected from the discontinuities' (reflectors') surface.
The reflected sound waves signal received by the transducer is then transformed back into an electrical
signal and its intensity is shown on the display unit.
The sound waves travel time can be directly related to the distance that the signal has travelled. From the
signal, information about reflector location, size, orientation and other features can be determined.
TWI Resources
Benefits
Materials characterization
Applications
Checking the quality of welds in pipes for the offshore oil industry
Aerospace industries
Military defence
Micro-Focus X-Ray
X-Ray equipment in which the focal spot size is less than 100 µm is referred to as microfocus unit. Advanced
micro-focus units have a focal spot size as low as 5 µm which is achieved by focussing the electron beam on
the target in combination with sufficient cooling to avoid overheating.
Micro-focus radiography facilitates to observe the minute details of the object through production of
magnified X-ray images, which in turn enhances the flaw detection capability which improves reliability in
comparison to conventional radiography. Micro-focus X-ray systems having focal spots that approach a point
source are useful in obtaining very high resolution images due to the negligible penumbra effect.
The X-ray source generates a continuous beam of X-rays from the very small focal point. The beam passes
through the sample placed on the manipulator turntable, and casts an X-ray projection onto the detector
sensor. The sensor converts the transmitted X-ray projection into a visible greyscale image, which is
displayed on a monitor. The magnification of the sample depends on its position between the X-ray source
and detector. Moving the sample towards the X-ray source increases the magnification and improves the
spatial resolution by increasing the number of pixels over which the X-ray image is projected. Even when
operating at maximum magnification, the micro-focus X-ray spot ensures the image is always sharp. The
associated software enables contrast enhancement and image integration.
TWI Resources
Benefits
Image Enlargement
Improved Radiographic contrast
Phased array ultrasonic systems utilise multi-element probes, which are individually excited under computer
control. By exciting each element in a controlled manner, a focused beam of ultrasound can be generated.
Software enables the beam to be steered. Two and three dimensional views can be generated showing the
sizes and locations of any flaws detected.
TWI's Resources
Zetec Tomoscan III. A flexible and powerful system capable of handling up to 128 channels of phased
array ultrasound channels
Peak NDT's Micropulse 5 PA system. This is an advanced unit developed for the nuclear industry with
128 channels
Portable units
Olympus NDT’s Omniscan MX PA. A robust 16 channel unit. (TWI owns 5 of these systems).
Harfang Microtechniques X-32. TWI owns 8 of these units. They are robust and extremely well adapted
to site use
Advantages
Beam focusing
Beam steering
Radiography Testing
In Radiography Testing the test-part is placed between the radiation source and film (or detector). The
material density and thickness differences of the test-part will attenuate (i.e. reduce) the penetrating
radiation through interaction processes involving scattering and/or absorption. The differences in absorption
are then recorded on film(s) or through an electronic means. In industrial radiography there are several
imaging methods available, techniques to display the final image, i.e. Film Radiography, Real Time
Radiography (RTR), Computed Tomography (CT), Digital Radiography (DR), and Computed Radiography
(CR).
There are two different radioactive sources available for industrial use; X-ray and Gamma-ray. These
radiation sources use higher energy level, i.e. shorter wavelength, versions of the electromagnetic waves.
Because of the radioactivity involved in radiography testing, it is of paramount importance to ensure that
the Local Rules is strictly adhered during operation.
Computed Tomography (CT) is one of the lab based advanced NDT methods that TWI offers to industry. CT
is a radiographic based technique that provides both cross-sectional and 3D volume images of the object
under inspection. These images allow the internal structure of the test object to be inspected without the
inherent superimposition associated with 2D radiography. This feature allows detailed analysis of the
internal structure of a wide range of components.
TWI Resources
TWI has the following digital radiography equipment with computed tomography capability to cater for
industrial needs.
Benefits
Applications
Radiographic Testing is widely used in the;
Aerospace industries
Military defence
Offshore industries
Marine industries
Power-gen industries
Petrochem industries
Waste Management
Automotive industries
Manufacturing industries
Transport industries
TWI has developed a highly capable automated inspection system suited to both research and development
work and production inspection.
Two six-axis arms deploy ultrasonic transducers allowing pulse echo and through-transmission ultrasonic
inspection of complex geometry components. The primary application for this technology is the inspection of
carbon fibre composites where defects such as delamination and voids can be detected, but other material
types can also be inspected.
TWI Resources
The heart of the automated inspection system is an inspection cell comprising two six-axis robotic arms,
capable of working independently and cooperatively. The robotic arms deploy end-effectors carrying
ultrasonic transducers (single element and phased array), mounted into water jet nozzles that provide
suitable water columns to guide the ultrasonic beams from the probes to the surfaces of the samples.
Software developed in-house synchronises the robot’s movement with the ultrasound signal acquisition. The
robots can be taught by teach pendant or via offline programming. An operator can load a CAD file matching
the inspected component’s geometry into a software application, and pick the areas to be inspected; the
software then generates the scan path for the robots.
The robot motion can be simulated in a 3D environment to verify non-collision between robot and part and
robot reach limits prior to actual deployment.
Benefits
General purpose to allow the deployment of different non-destructive testing inspection probes
Applications
Thermography
Thermography uses a camera containing large numbers of infrared sensors which can detect and measure
small temperature differences. The image showing these differences can be downloaded to and displayed on
There are two basic types of thermography; passive thermography and active thermography.
In passive thermography, the camera is simply pointed at the test piece and from the thermal image a
temperature map is constructed. Active thermography involves heating the surface of the object rapidly
using an external heat source and observing how the temperature decays with time. Flaws in the material
show up by variations in the temperature decay rate.
TWI Resources
Active thermography – Thermal Wave Imaging EchoTherm™ Pulsed Thermography (PT) system
Benefits
Applications
Aerospace industry including sandwich panels, carbon/epoxy composites and delamination/impact
damage
Automotive industry including composite structures, spot welds and adhesive bonds
Power industry including wind turbine blades, coating uniformity and delamination in composites
Time-of-Flight Diffraction
In time-of-flight diffraction (ToFD) systems, a pair of ultrasonic probes are used, sitting on opposite sides of
a weld-joint or area of interest. A transmitter probe emits an ultrasonic pulse which is picked up by the
receiver probe on the opposite side. In an undamaged part, the signals picked up by the receiver probe are
from two waves: one that travels along the surface (lateral wave) and one that reflects off the far wall
(back-wall reflection). When a discontinuity such as a crack is present, there is a diffraction of the ultrasonic
sound wave from the top and bottom tips of the crack. Using the measured time of flight of the pulse, the
depth of the crack tips can be calculated automatically by trigonometry application. This method is even
more reliable than traditional radiographic, pulse echo manual UT and automated UT weld testing methods.
ToFD offers great accuracy for measuring the critical through-wall size of crack-like-defects. The accuracy
of greater than ±1mm can be obtained in a wide range of material thickness from which pressurised
components are constructed.
ToFD was initially developed as a method of accurate monitoring and sizing of through-wall height of in-
service discontinuities in the nuclear industry. It has now been independently validated as one of the most
effective techniques for locating and sizing discontinuities in ferritic welds.
TWI Resources
TWI has extensive R&D and field experience on ToFD application for defect growth monitoring, inspection of
welds in gas storage bullet, nozzle inspection, ToFD application in lieu of radiography testing (RT) for
pressure vessel and piping welds, detection of thermal fatigue cracks, inspection of turbine and generator
components, in-service inspection for flaw detection and sizing as part of FFS assessment.
Olympus MX
Olympus MX2
Zetec Dynaray
GE Phasor XS
Benefits
Planar discontinuities, which are not perpendicular to measured surfaces can be detected
Applications
Nuclear industries
Manufacturing industries
Inspection of bridges