Mark, could you share what initially drew you to the field of Non-Destructive Testing (NDT) and ultrasonics? Was there a specific moment or experience that sparked your interest?
Well, my journey into Non-Destructive Testing and ultrasonics was quite serendipitous, to be honest. Following my PhD in spectroscopy at Durham, I applied for a related post-doc position at Cranfield. While I didn't succeed in securing that particular role, a member of the panel recognised my potential and offered me a position in MEMS (Micro-Engineered Mechanical Systems). This role had a strong ultrasonic component, which piqued my interest. Transitioning to the ultrasonics group at Warwick was a pivotal moment for me, as it immersed me in the practical applications of NDT within various industries.
Coming from a background in farming, I found great satisfaction in working on technologies with tangible real-world applications. This passion eventually led to the establishment of our spin-out company, Sonemat Limited, in 2005, aimed at commercialising the research output of our group. It's been a fulfilling journey, and I'm grateful for the opportunities that have brought us to where we are today.
As someone deeply immersed in the world of ultrasonics, could you simplify for our readers how EMATs (Electromagnetic Acoustic Transducers) function and what sets them apart from traditional ultrasonic transducers?
Absolutely, let me break it down for you. Traditional ultrasonic transducers (primarily piezoelectric) rely on the piezoelectric effect to generate or detect ultrasound within the probe. This process involves converting an electrical pulse into a mechanical displacement, or vice versa. The challenge then lies in transmitting this ultrasound from the probe to the target material being inspected. This usually requires direct physical contact with a coupling fluid to enhance transmission.
Now, let's talk about EMATs (Electromagnetic Acoustic Transducers). Unlike traditional transducers, EMATs operate in a unique way. Instead of generating sound within the probe, EMATs produce a magnetic field pulse. This magnetic field interacts with the material under inspection, essentially turning its surface into a speaker. This innovative approach eliminates the need for physical contact with the material being inspected, which is particularly advantageous in situations involving hot or rapidly moving components.
Furthermore, the ability to manipulate magnetic fields allows us to generate waves that are challenging to produce externally and couple into the material. While this method may not always be the most efficient, its distinct advantages often outweigh any efficiency concerns, especially in scenarios where physical contact is impractical or where precise wave manipulation is required.
At Sonemat, you've been instrumental in developing solutions for crack detection and preventative maintenance. Can you share a memorable success story where your technology significantly improved operations for a client?
While I must respect confidentiality agreements, I'm delighted to share some impactful success stories:
We've collaborated with a leading UK inspection company to develop ultrasonic probes utilising innovative techniques. These probes enable operation at extremely high temperatures and in hostile environments, revolutionising in-service tank wall inspections.
Another UK-based inspection company, specialising in deployable fill-level monitoring, has harnessed Sonemat technology to enhance the dimensional range of vessels for fill-level measurements. This advancement has significantly improved their monitoring capabilities.
Additionally, a European marine engine monitoring company has adopted Sonemat's licensed EMAT technologies. This solution facilitates easily installed and reliable condition monitoring of moving parts on ship motors, enhancing operational efficiency and reliability.
These success stories underscore our commitment to delivering cutting-edge solutions that drive operational excellence and empower our clients to overcome complex challenges in their respective industries.
In your experience, what are some of the most common hurdles companies encounter when it comes to NDT inspections, and how does Sonemat tackle these obstacles with its innovative ultrasonic solutions?
From my experience, the most common hurdles in NDT inspections revolve around time constraints and deployment challenges. Time is not only a cost factor, as NDT inspectors need to be compensated, but also because equipment downtime during inspections can impact productivity. Additionally, the deployment of inspection technologies can be complex, especially when it's not prioritised during the design phase of structures.
At Sonemat, we address these challenges head-on with our innovative ultrasonic solutions, particularly our expertise in EMAT technology. EMATs offer non-contact operation, which significantly streamlines deployment and accelerates inspections, particularly when utilising guided waves. These waves are notoriously challenging to couple into and out of the inspected material using traditional methods. Furthermore, the electromagnetic coupling of EMATs means they can be utilised on hot, dirty, or coated surfaces with ease, further enhancing deployment flexibility.
With technology evolving rapidly, what recent advancements in NDT, particularly in ultrasonics, have caught your attention the most?
Recent advancements in ultrasonics that have caught my attention include the use of greater signal encoding, resulting in improved signal-to-noise ratios and safety benefits. Additionally, the development of inexpensive autonomous networked embedded sensors for long-term structural health monitoring is particularly noteworthy, offering cost-effective solutions and the potential for real-time process control.
Challenge yourself to innovate and push boundaries. Get out there and improve things, come up with new ideas! Be the change that you want to see in the industry.
- Dr. Mark David George Potter
Sonemat is known for its expertise in high-temperature applications. How do you and your team ensure that ultrasonic inspections maintain accuracy and reliability in such extreme conditions?
In high-temperature applications, maintaining ultrasonic inspection accuracy and reliability is crucial, despite the challenges posed by extreme conditions. The variability of sound velocity and attenuation in hot materials, coupled with potential probe damage, are primary concerns. To address these, we employ several strategies:
Temperature measurement and correction: We monitor temperature variations and adjust ultrasonic velocity accordingly to ensure accurate readings.
Probe protection: While conventional probes may suffer in high temperatures, EMATs offer advantages due to their non-contact nature. Nonetheless, we implement strategies like active water cooling, brazed connections, and special high-temperature magnets capable of operating up to 500°C without cooling.
Take us through the journey of creating a new ultrasonic NDT solution at Sonemat. From the initial idea to its practical implementation, what does the process look like?
Typically, the journey begins with industry-driven demand. NDT inspection companies approach us with specific needs or challenges, such as the ability to perform certain inspections without plant shutdowns. Our response is always proactive: 'Perhaps, could you provide us with samples for testing or lend us equipment for experimentation?'
This initial phase allows us to assess feasibility and determine the additional development required to meet the client's requirements. Subsequently, we embark on a rigorous process of testing, development, and optimisation, conducted in increasingly realistic environments. This iterative approach ensures that our solutions are not only technically feasible but also practical and effective.
Once we have refined the prototype through field trials and gathered valuable feedback, we move towards finalising the product. This may result in a bespoke solution exclusive to a particular client who has sponsored the development, or a new commercially available product developed in response to industry demand.
Collaboration is key in delivering tailored NDT solutions. How does Sonemat engage with industries to understand their unique challenges and develop customised approaches?
Through our active participation in industry-focused groups like RCNDE, DRDI, and NDEvR, as well as leveraging the extensive industrial network of our co-founder, Professor Dixon, Sonemat regularly receives inquiries from industrial partners seeking solutions to specific NDT challenges.
We approach each collaboration with an open mind and a commitment to flexibility. Recognising that every industry and application is unique, we prioritise understanding our client's specific needs and requirements. Rather than offering a one-size-fits-all solution, we invest the time and effort to tailor our approach to ensure the best possible outcome for our clients. At Sonemat, we believe that true innovation emerges from collaborative partnerships, and we are dedicated to working closely with industries to develop customised NDT approaches that address their unique challenges effectively.
Looking ahead, how do you envision automation and robotics shaping the future of NDT inspections? And what role does Sonemat play in driving this technological advancement?
Anticipating the future, automation and robotics are poised to revolutionise NDT inspections. Advancements in data processing, transmission, and storage are driving the emergence of 'smart' NDT technologies, capable of recognising patterns indicative of potential hazards. We foresee a shift towards compact systems with onboard processing power, enabling real-time analysis and decision-making.
At Sonemat, we are actively contributing to this technological evolution with our next generation of digitally integrated solutions. Our focus is on developing user-friendly, digitally enabled technologies with ubiquitous digital and telemetric outputs. By simplifying data collection and analysis processes, we aim to empower NDT inspectors with the tools they need to conduct more efficient and effective inspections, ultimately enhancing safety and reliability across industries.
Finally, Mark, reflecting on your journey in this field, what advice would you offer young professionals aspiring to make their mark in NDT and ultrasonics?
The NDT field tends to become stagnant, so challenge yourself to innovate and push boundaries. Get out there and improve things, come up with new ideas! Be the change that you want to see in the industry.
