Table of Content
- Future of NDT Testing
- Emerging Technologies in NDT
- Potential Use of NDT in Uninhabitable And Hazardous Environments
- Robotics in Non-Destructive Testing
Non-Destructive Testing (NDT) has been pivotal in ensuring the safety and integrity of structures, machinery, and materials across various industries. Emerging technologies and changing trends are driving significant advancements in the field of NDT as technology develops. NDT encompasses a range of techniques employed to evaluate the properties of materials, components, and structures without causing any damage.
Future of NDT Testing
The 21st century has led to the inception of the Fourth Industrial Revolution or 4IR. This industrial transition has adopted the use of automation, optimization of processes, improved data management, communication, and connectivity between processes. The need for human involvement is hence reduced and systems are encouraged to automate maintenance, monitoring, troubleshooting, and general operation using advanced software resources, sensors, embedded systems, the Internet of Things, Artificial Intelligence, and machine learning.
The vast data obtained with the aid of the aforementioned resources in making manufacturing processes and factories ‘smart’ provide active control of the process and machinery and can predict potential failures and maintenance requirements. The automated value chain mapping enables efficient production, operation, and flexibility in systems, which allows customization, and precision. Industry 4.0 also focuses on data transparency by collaborating the operational data of the enterprise with the factory floor analytics.
Non-destructive Testing Methods have become a focal point with respect to the advent of Industry 4.0. Improvement of existing technology involves the adoption of embedded systems, advanced sensors, cloud computing for ease of data storage and access, artificial intelligence used for improved analytics, error-free inference, coordinated process flow, and efficient troubleshooting. Advanced techniques help with clearing the obstructions created by complicated Non-destructive Systems which require a deep understanding of the process, specific training, and significant experience on the operator’s parts.
Automation and Artificial Intelligence generalize processes and analyses trends in the operation to gauge and estimate the most convenient plan of action. The probability of human error caused due to manual positioning, assembly, and installation is also minimized or eliminated using modern sensors and hence streamlines workflows by reducing iterations required to obtain accurate and standardized readings as per industry standards. Data interpretation is also streamlined and automated by using modern technologies, hence avoiding the chance of recording and evaluation errors.
Procedural data is meticulously documented, hence the workflow and potential deviations from the standard procedure can be detected using these technical upgrades. Automation and cloud storage provide organizational access to testing data and reduce the time consumed in data processing and communication across the organization. It also provides the option of data encryption for security, inspection of data post-analysis, and quick access to old test results. ND Hazardous Environments Hazardous Environments is a reliable and rapidly growing industry that is beneficial to many industries, for testing a variety of materials and is viable for a variety of working environments, hence the field is subject to extensive research and development.
Emerging Technologies in NDT
Emerging technologies in NDT include artificial intelligence, robotics, and advanced sensors that are revolutionising the way inspections are conducted. These technologies offer increased accuracy, efficiency, and safety in NDT testing procedures.
1. Advanced Sensors and Instrumentation
With the advent of advanced sensors and instrumentation, NDT is witnessing a paradigm shift. Sensors equipped with cutting-edge technologies such as Internet of Things (IoT) connectivity, artificial intelligence (AI), and machine learning (ML) algorithms enable real-time monitoring and analysis of assets, leading to proactive maintenance strategies.
2. Robotics and Automation
Robotics and automation are revolutionising NDT by enhancing inspection capabilities and efficiency. Autonomous drones, crawlers, and robotic arms equipped with NDT sensors can navigate complex environments and perform inspections with unparalleled precision, minimising human intervention and ensuring safety in hazardous conditions.
3. 3D Printing and Additive Manufacturing
The widespread adoption of 3D printing and additive manufacturing techniques has created new challenges for NDT. New nondestructive testing methods are being developed specifically for checking additive manufacturing parts. These methods can find flaws like holes, cracks, and delamination even in parts with complicated shapes.
4. Augmented Reality (AR) and Virtual Reality (VR)
AR and VR technologies are revolutionising the way NDT inspections are conducted and interpreted. Immersive visualisation tools enable inspectors to overlay digital data onto physical assets, facilitating real-time analysis and decision-making. Moreover, Augmented Reality-based training simulations enhance the skills of NDT professionals, ensuring proficiency in complex inspection tasks.
Get More Information About, Top Emerging Technologies in 2024
Potential Use of NDT in Uninhabitable And Hazardous Environments
NDT provides a myriad of techniques that are relatively simple to automate and integrate with robotic systems. These mobile mechanisms, with advanced movement patterns and sensors, can be used to access structures and machinery in treacherous and hazardous environments.
These technologies save human involvement and risk to human life in dangerous situations while maintaining testing standards and ensuring the structural integrity of test subjects. Non-destructive testing techniques that can be automated include Visual Inspection, Ultrasonic Testing, Phased Array Ultrasonic Testing, Time of flight diffraction, and Eddy Current Inspection.
Use of Non-destructive Testing Techniques in the Environment
NDT Techniques can be used in the following environments:
1. Chemically hazardous work environments:
Extended exposure to chemicals in a workplace may cause workers long-term and fatal illnesses. Multiple industry standards are set in place regarding chemical exposure limitation, chemical safety protocols, and occupational gear for workers. Robots and machinery are replaceable, unlike human life and safety, hence chemical-resistant robots can be used, in conjunction with NDT apparatus.
2. Work environments with particulate pollution in the air:
Particulate matter suspended in the air can be inhaled and ingested by workers, causing severe organ damage (including lungs, heart, and bones). Dust may include lead, cement, silica, wood, flour, mold, etc. Robots, on the other hand, may fit with sensors (IP65) and be made dustproof eliminating the need for human workers to be exposed to such hazards.
3. High-noise work environments:
Occupational Safety and Health Administration (OSHA) laws and ISO 1999-1990 set strict standards for sound exposure limits for workers (a limit of 85dB for a period of 8 hours and a general upper limit of 140dB) to prevent long-term damage to hearing. Robots can provide remote access to such an environment, and testing can be conducted without causing harm to the operators. The operation of these robots can also be automated to eliminate the need for human presence.
4. High Altitude work environment:
Architectural and civil engineering advancements have led to the construction of increasingly and alarmingly tall structures. These structures are exposed to strong winds and natural elements, which may cause damage and weakening of the structure. Testing such structures at the upper regions which may have low atmospheric oxygen is not feasible for human operators and can cause pulmonary edemas and altitude sickness. NDT robots can prevent these issues and the risk of high-altitude fall-related accidents while maintaining thorough monitoring of the integrity of the structure.
5. A work environment with exceeding temperatures:
As per workplace regulations, standard habitable temperatures should be maintained in a workplace to prevent heat strokes among workers. However, if the temperature of the workplace exceeds 80°C, it is a matter of caution as it can cause excessive fatigue. At temperatures above 90°C, there are risks of heat strokes and organizations need to proceed with extreme caution while engaging workers in those regions. Robots can be equipped with temperature-resistant suits that can operate in high-temperature regions. IP69K sensors and actuators are installed in such mechanisms to enable the heat and pressure resistance of the testing apparatus.
6. High radiation exposure environments:
The Chornobyl nuclear reactor and the Fukushima nuclear reactor post accidents are some examples of heavy radiation zones that are inaccessible to humans without fatal radiation damage or long-term illnesses. These zones however needed to be accessed to curb damages and ensure safety. Robots such as the Joker were used in Chernobyl to replace humans for carrying out important clearing procedures, whereas the Fukushima plant also employed the use of robots for inspection of the radiation-affected zones.
The acceptable radiation dosage for a human being as per the World Health Organization is only 50mSv a year, however, the increase in the use of nuclear energy and Nuclear Power Plants in modern-day technology demands that such heavy radiation zones be created. To ensure safety and stability, without risking human life, radiation-proof robots are employed with Non-destructive Testing apparatus to ensure the safety and smooth operation of such facilities.
6. Testing environments in deep water:
Deepwater optical cables, petroleum industry rigs, ocean exploration, and nuclear power plants involve the presence of heavy machinery in deep water regions. The pressure in such regions is way above the permissible rate for professional divers. Human inspection and maintenance are difficult in such setups, hence deep sea robots are utilized. These robots also possess a higher range of motion than humans and can be used for multiple testing procedures.
Robotics in Non-Destructive Testing
The use of robots is beneficial for multiple NDT procedures like that of Radiography Testing. The highly penetrative X-rays and gamma rays pose multiple challenges that may hinder the accuracy of results. Robots are not limited by work hours or labor laws and can hence be used for round-the-clock NDT and analysis.
1. Advanced Materials
The discovery and invention of new materials and composites create a need for new testing methodologies to ensure quality and integrity for manufacturing and service industries. Research and use of advanced sensors and embedded systems aid in the efficient analysis of such material so that advancement in its usage can be expedited and the benefits of these newer materials can be thoroughly utilized by newer technologies and structures.
2. Space Industry
The Terahertz (THz) Technology is a new age non-destructive testing methodology used by NASA to test Space Shuttle tiles for corrosion. This Technique is no-contact and offers high-resolution results. This device operates between a frequency of 300GHz and 3THz. It can detect corrosion defects of a depth of approximately 0.13mm. Shuttle tiles are non-conductive and undergo harsh extremities ranging from the vacuum in space to marine landings and can be subject to Corrosion which is imperative to be detected and moderated. Terahertz is a heavily researched methodology that can help ensure space shuttle safety.
3. Oil and Gas Industries
The Total Focusing Method (TFM) is an advanced technique of Phased Array Ultrasonic Testing that aids in the detection of hydrogen damage in test materials. The testing apparatus is portable and provides high-resolution images, accurate readings, simplified characterization of data, greater test zone coverage, slope visualization, and reduction of the dead zone.
The Total Focusing Method (TFM) uses the induced ultrasonic energy and divides the test zone into pixels, extracting time of flight diffraction and amplitude data from each pixel. The amplitude data is summated for N(receivers) x N(emitters). This data is extracted for every pixel in the zone, hence providing rich resultant data.
4. Data Management
The Big Data industry highly benefits from NDT as the advancements in the field lead to larger data sets and create the need for better data management. Ready access to old testing records aids in calculating data trends and can increase the sensitivity of the non-destructive testing mechanism.
5. Advanced Manufacturing
Companies that utilize High-Value Manufacturing methodologies, utilizing technical, skill, and knowledge-based processes to generate significant value and maintain novelty in innovativeness require NDT Methodologies in their main capabilities.
Some of those capabilities include:
Resource Efficiency
- Energy Generation Technologies
- Sustainability and through-life design and manufacturing
- Lightweight products, vehicle, and structure manufacturing
- Processing of biotechnical, biological, and synthetic biology
Manufacturing Systems
- Process capability in food, chemical, and pharmaceutical production
- Small-scale design and manufacturing
- Modeling of systems, simulation, and design
- Automation, mechanization, and interfaces
- PnP manufacturing
- Mechanical conversion for process optimization
- Design, manufacture, and inference of products
Materials Integration
- Smart, Hybrid, and composite materials
- Smart systems and embedded systems
- Advanced coating parameters
Manufacturing Processes
- Flexible Manufacturing Systems
- Parallel Engineering
- Additive Manufacturing (SLA manufacturing or 3D printing)
- NNS manufacturing (Near Net Shape)
Business Models
- Fragmented chain management to support high-value manufacturing.
- Building new business models with flexible arrangements to create and support high-value manufacturing.
- Developing and retaining skills to support high-value manufacturing.
- Managing risk and resilience to support high-value manufacturing.
References
1. Frost & Sullivan
2. Nexxis
3. Verified Market Reports
4. Eddyfi
5. Bimplus
