Frontiers of Research in NDE Baldev Raj Hon. Member, ICNDT - - PowerPoint PPT Presentation

Frontiers of Research in NDE

Baldev Raj

• Hon. Member, ICNDT

Distinguished Scientist and Director Indira Gandhi Centre for Atomic Research Kalpakkam - 603 102, India

Outline

International scenario Frontiers of Research - Introduction Mission and Vision of Indira Gandhi Center for Atomic Research (IGCAR) Evolution of Centre of Excellence in NDE Multi-disciplinary Research Synergism at IGCAR

Research

Research is original investigation to Gain new insights Enhance understanding Invent Improve the existing Unique measurements Exploring scientific answers/explanations Research should aim to Enhance ecological balance Enhance quality of life on the earth

Research is based on sound principles, instruments, models

International scenario: A Glimpse

• High dB MEMS and NEMS
• Synchrotron-tomography
• Sampling phased array (enhanced SAFT & TOFD)
• Positron annihilation measurements
• Acoustic microscopy
• High temperature characterization of materials –

ultrasonics & acoustic emission

• Sub-surface / remote NDE (GPR, GMR, GMI)
• Nano structures, Bio materials and Smart materials
• Terahertz imaging
• Multi-Sensor networks
• Knowledge Management

Frontiers of Research in NDE

Continuing education

Acceptance Experience Knowledge Management Standards Issues: Cost Efficiency Reliability Robustness Relevance

New Designs, Concepts, Theories, Insights Measuring the Immeasurable earlier Innovative Materials, Instruments, Sensors Training & certification

Futuristic pro-active research / solution/ realisation

Frontiers of Research

Create revolutionary designs / concepts/ materials/ technologies/ devices that change the face of life Think unthinkable/ impossibilities/ un-measurable Undertake futuristic pro-active research for the betterment

• f mankind

Realisation of the imaginations/ understandings Aiming solution to mysteries, miseries & calamities Enhance synergy across disciplines and diverse societies

• 6

10

• 8

10

• 10

10 1A 100A

1μm

MICROSTRUCTURE / DEFECT [m] 10

• 4

10

• 2

m

100μ

10mm

Frontier Research Dimensional Space

Nano Micro Meso Macro

NDT TECHNIQUES 10 100A

• 10

1A 10

• 8

10

• 6
• 2

10mm

10

• 4

10 [m]

1μm

m

100μ

Plethora of NDE Techniques

Nano Micro Meso Macro

Role of Cross Domain Research

In general, research is focused in one domain, which has limited applicability. But, by comprehending across domains and performing measurements with good correlations, better success and recognition is possible Demonstrative examples include – NDE of dislocation dynamics/ Grain boundaries / precipitates – NDE for yield strength, fracture toughness, ductile-to- brittle-transition temperature – Multi-sensor Data Fusion (sensors, signal & image processing)

Example: Dislocation Dynamics

A few relevant NDE Techniques

• Magnetic Barkhausen emission
• Acoustic Emission
• Ultrasonics
• Infrared Thermography
• Positron Annihilation etc.

Each Technique gives different information and limited understanding. Comprehensive understanding is possible by Sensing with feedback Use of integrated sensors Data Fusion

Multi-sensor Networks: Data Fusion

The success of medical NDE can be attributed to the single- component i.e. human body, as compared to engineering components comprising of many – materials – processes – types of defects A few diagnostic checks reveal overall health e.g. MRI measurements at tissue level - gross output is understanding Directed research with mega funding has enabled solutions to challenging diagnostic problems. Suggested Parallel Approach for Engineering For engineering components, multi-sensor networks obtaining NDE data on components from atoms, dislocations, grain boundaries, welds etc. and employing Data Fusion are expected to enable continuous monitoring & assessment of structural integrity

Enrichment of Frontiers of Research

Stay competitive in domains to meet the challenges with confidence Frontiers of research should take cognizance

• f technology forecasts

Attract young researchers Formulate research problems in discussion with industry Encourage multi-disciplinary and multi- society research

Role of Communication in Frontier Research

A strong need exists to establish and maintain good communication with

Industry Young Educationalists Policy makers Society Media

Frontiers of Research: Our Approach

Formulate applied research problems on known themes & directions – Road less traveled Explore interdisciplinary and cross-country perspectives, preferably international Publish monographs and books with inspiring status articles and perspectives Define proposals under the working groups on educational & research, ICNDT, World Federation of NDE Centers and others To present and share the excitement of successes and lessons learnt from failures

Indian Approach

85 82 80 75 71 67 60 90 86 84 84 79 75 69 72 89 50 55 60 65 70 75 80 85 90 95

1995-96 1996-97 1997-98 1998-99 1999-00 2000-01 2001-02 2002-03

A vailab ility/C ap acity F actor (% ) ----->

THREE STAGE NUCLEAR POWER PROGRAM THREE STAGE NUCLEAR POWER PROGRAM

Stage Stage – – I PHWRs I PHWRs

• 15

15-

• Operating

Operating

• 5

5 -

• Under construction

Under construction

• Several others planned

Several others planned

• Scaling to 700 MWe

Scaling to 700 MWe

• Gestation period

Gestation period being reduced being reduced

• POWER POTENTIAL

POWER POTENTIAL ≅ ≅ 10,000 MWe 10,000 MWe

LWRs LWRs

• 2 BWRs Operating

2 BWRs Operating

• 2 VVERs under

2 VVERs under construction construction Stage Stage -

• II

II Fast Breeder Reactors Fast Breeder Reactors

• 40 MWth FBTR

40 MWth FBTR -

• Operating

Operating Technology Objectives Technology Objectives realised realised

• 500 MWe PFBR

500 MWe PFBR-

• construction commenced

construction commenced

• POWER POTENTIAL

POWER POTENTIAL ≅ ≅ 540,000 MWe 540,000 MWe

Stage Stage -

• III

III Thorium Based Reactors Thorium Based Reactors

• 30 kWth KAMINI

30 kWth KAMINI-

• Operating

Operating

• 300 MWe AHWR

300 MWe AHWR-

• Under

Under Regulatory Examination Regulatory Examination

• POWER POTENTIAL

POWER POTENTIAL ≅ ≅ Very Very

• Large. Availability of ADS
• Large. Availability of ADS

can enable early can enable early introduction of Thorium on introduction of Thorium on a large scale a large scale

Indian Energy Growth Scenario

COAL Th-FBR U-FBR OIL GAS HYDRO U-PHWR

Electricity Generation (GWe) 126.09 Nuclear Energy Share (GWe) 3.90 PHWR (GWe) 3.58 Faster Growth is needed to reach the target FBR with Closed Fuel Cycle is inevitable

June 2006 2052

~ 1344 ~ 275 ~ 0

5305 3699 2454 1620 1000 613 1000 2000 3000 4000 5000 6000 2002 2012 2022 2032 2042 2052 Time period P e r C a p ita G e n e ra tio n (k W h )

Resource Potential

India’s Energy Resources (BTCE) Nuclear Reactors in the World

INDIA WESTERN EUROPE NORTH AMERICA

12000 6000 660

WORLD AVERAGE

2 2

Indices of socioeconomic development like literacy, longevity, GDP and human development (Per capita energy consumption)

kWh/a

India’s Nuclear Energy

Indira Gandhi Centre for Atomic Research

To conduct a broad-based multidisciplinary programme of scientific research & advanced engineering development, directed towards establishing Sodium Cooled Fast Breeder Reactors (FBR) in the country. Technology to close the fuel cycle in a cost-effective and environmentally friendly manner. Education, training and human resources development for building scientific excellence in the country.

MISSION VISION

Global leadership in FBR science and technology by 2020

Multi- disciplinary Research at IGCAR

In-service Inspection Life Management Clinical Diagnostics Conservation

• f Cultural

Heritage Quality Assurance Smart materials & Sensors Robotic devices Material Characteri- zation

1980’s

CENTRE FOR EXCELL- ENCE

DEDICATION VISION SYSTEMATIC EXPERIMENTATION

Multi-disciplinary Professionals Understanding Material Degradation Identifying Critical Areas Instrumentation& Sensors Field Implementation Modeling & Software Validation

NDE Science & Technology

Successful Flight to Excellence Robustness Success

• IGCAR

Personnel Training

Centre of Excellence in NDE

Accomplishments

• Wide spectrum of NDE techniques under single-roof
• 500 publications in peer reviewed journals
• 15 patents
• 20 books

Professional Leadership in area of NDE Responsible for nurturing NDE Centers at IIT (Chennai, Kanpur) and NML (Jamshedpur) Evolved cutting-edge technologies for solving challenging NDE problems in strategic and core sectors International Linkages Fraunhofer Institute of NDT (IZFP), Saarbruecken BAM, Berlin CNDE, Iowa State University, USA Michigan State University, USA Huddersfield University, UK University of Cardiff, UK

Nano-technology for NDE

Magnetic Nano-particles and Ferro-fluids Magnetic nano-particle based devices and optical probes for NDE Development of leak-free sealants Synthesis of magnetic nano-particles with enhanced transition temperatures Ultrasound velocity measurement for obtaining insight into the complex structures formed in nano- fluids Fundamental understanding of molecular interactions using a force apparatus (minimum force measurable is 10-13 N)

Magnetic field vs. ultrasonic velocity in a magnetic nanofluid

Magnetite particles (~ dia. 8 nm) coated with an organic layer of surfactant and dispersed in a carrier fluid Above some concentration, an increase in ultrasound velocity (Δc) is observed in the presence of magnetic field due to formation of one dimensional ordering of magnetic particles Δc depends on magnetic field strength, magnetic fluid concentration and field direction

Δc for wave propagation (a) along the direction of magnetic field (b) Perpendicular

Without field With field

200 400 600 800 1000 1200 1400

40 50 60 70 80 90 100 110

2θ (degree) Intensity (a.u)

Ethanol/water ratio 0 : 100 20 : 80 40: 60 60 : 40

XRD patterns of samples

• btained with different

ethanol-water ratio

20 nm

2 4 6 8 10 12 14 10 20 30 40 50

Distribution (%) Particle diameter (nm)

TEM image of magnetite nanoparticles (left) and size distribution (right)

• 25
• 15
• 5

5 15 25

• 8
• 6
• 4
• 2

2 4 6 8 Magnetic field (kOe) Magnetization (emu/g) 4.8 nm 600

0C

25

0C

700

0C

• 0.8
• 0.3

0.2 0.7

• 8
• 6
• 4
• 2

2 4 6 8 700

Magnetization curves obtained for 4.8nm magnetite sample before and after heat treatment at 600 and 700oC. Inset of the figure shows the magnified view of the magnetization curve after 700 oC heat treated.

Synthesis of magnetite nanoparticles with enhanced transition temperatures

New Technology Development

J.Philip…..Baldev Raj, Indian Patent 501/MUM/2002

• A unique technique for in-situ measurement of weak forces (10-11 to 10-13 N)

between emulsion drops (J.Philip…Baldev Raj; Physical Review Letters, 2002 & Langmuir 2002 )

• First experimental evidence for stretching and collapse of polymer layers

under association with ionic surfactants (J.Philip…..Baldev Raj; Macromolecule, 2003 & Phys. Rev. E 2002)

• Based on the force data a new process was invented to enhance the

stability of ferrofluid emulsions, which can be extended to other products too

10-13 10-12 10-11 40 60 80 100 120 140 160 180

0 mM 0.2 0.53 0.72 1.33 2.66

Force (N) Interdroplet spacing (nm)

Repulsion between the emulsion drops is extended by using polymer-surfactant complexation

Ferro-fluid based Dynamic Seals

Seal constituents: Fe3O4 nanoparticles of 5-10nm diameter, coated with a monolayer of surfactant and dispersed in a carrier liquid

Pole-piece with multiple stages for vacuum sealing

• Pole-piece with multiple stages/teeth
• Each stage, DP = 0.2 Atm.

Dynamic seal assembly

Ferro-fluid assumes the shape of a "liquid O-ring" and produces a hermetic seal Advantageous Features *Low viscous drag *100% torque transmission *Non-contaminating *High speed capability *Immeasurable leakage

Tunable Optical Filter

Influencing factors

• Droplet size
• Surfactant concentration
• External magnetic field
• Poly-dispersity
• Particle concentration

Filter based on Magnetic nano-particle based emulsion Capable of continuous tuning of wavelength in the UV-Visible-Near IR range Origin of the colors is due to Bragg scattering from the droplet chains in ferrofluid emulsion, formed by external magnetic field Advantages

• Device suitable for selecting

wavelengths in UV, visible and IR regions

• A single filter can be used for a range
• f central wavelengths, by adjusting

poly-dispersity

• Tuning can be achieved easily by

changing magnetic field strengths

J.Philip J.Philip… …Baldev Baldev Raj Raj; Patent 2002; ; Patent 2002; Meas. Sci. Tech. 14, 2003

Optical probe for defect detection

• A new NDE optical sensor for detection

and quantitative evaluation of defects

• Colour change in the ferrofluid emulsion

cell due to Bragg scattering from the droplet chains, formed by the magnetic flux leakage in presence of a defect Advantages: Non-contact No surface preparation No need for demagnetization No cleaning to remove adhered particles Easy quantitative analysis of defects, by mapping the wavelength and intensity J.Philip..Baldev Raj; Patents 186620 &186574; Meas.Sci.Tech. 10, 1999; NDTE, 33, 2000

Mechanical Seal, heat transfer, dampers etc. Sensors Inclinometers, accelerometers, flow meters, tilt, vibration, pressure and level sensors etc. Optical Defect detection, tunable optical filters, photonic band gap crystals, optical switches, etc. Biomedical Drug delivery, cell labeling, MRI contrast agent, cancer therapy, biosensors etc. Electronic Magnetic data storage, micro-contact printing, Nano-devices, etc Other Catalysis, anti-microbial coating, storage…

Technological applications of Magnetic nanofluids

NDE USING SQUIDs

SQUID output vs distance of the weldment sample after magnetisation

• 5

5 10 15 50 100 150 200 250 300 Distance (mm) SQUID output (฀ 0)

15.2954 ฀ 0 6.67455 ฀ 0 5.26860 ฀ 0 4.89565 ฀ 0 3.90938 ฀ 0 3.90857 ฀ 0

* virgin * 50 cycle * 100 cycle * 150 cycle * 200 cycle * 250 cycle

Sample : Stainless steel 316 L(N) Temperature : 600 oC, Strain rate : 3x10-3s-1

SQUID output Vs No. of cycles

• f the weldment sample

2 4 6 8 10 12 14 16 18 50 100 150 200 250 No of cycles SQUID output (฀ 0)

X-Y Scanner IGCAR- SQUID

200 300 400 500 600 8.05 8.10 8.15 8.20 8.25 8.30 8.35 8.40 8.45 8.50 8.55

SQUID OUTPUT (V) Angle of rotation (degrees)

• 30
• 20
• 10

10 20 30

Flaw width:1 mm Height 7 mm; Computed with 2D-exciter

Bnormal (nanoTesla)

FINITE ELEMENT SIMULATION OF SQUID-BASED EDDY CURRENT NON-DESTRUCTIVE EVALUATION OF CYLINDRICAL TUBES Pattabiraman et al

1

Source

iσω μ ⎛ ⎞ ∇× ∇× = − ⎜ ⎟ ⎝ ⎠ A J A

Various LCF stage identified by MBE

• 1. Cyclic Hardening
• 2. Cyclic Softening
• 3. Saturation
• 4. Crack Nucleation
• 5. Fracture

Δε t/2

± ± ± ± ±

± ← Virgin

1

Progressive accumulation of fatigue damage detectable Barkhausen Emission occur during movement of magnetic domain walls 9Cr-1Mo Steel MBE coil, 68 dB

1 2 3 4 5

Magnetic Barkhausen Emission- Low Cycle Fatigue

Micro- magnetic NDE instrument developed in- house

NDE FOR QUALITY ASSURANCE

Sodium is used as coolant in FBRs In Steam Generator Shell side - Sodium Tube side - Water Sodium-water reaction is highly exothermic Plant availability depends on SG Stringent NDE needed Steam Generator (SG)

• A crucial component in FBRs

Reliable eddy current, radiography and acoustic emission technologies developed, validated and implemented

Magnetic Barkhausen Emission (MBE) for Assessing Post Weld Heat Treatment

• MBE peak height across the weld indicates a significant difference in

hardness in the weld, HAZ and base metal regions

• After PWHT, the MBE peak height becomes constant (supported by the

hardness values)

• Detailed analysis established that MBE can be used to ensure the

effectiveness of PWHT Variation in MBE peak height across the tube- to-tube sheet weld joint, before and after post weld heat treatment

Time of Flight Diffraction (TOFD)

• TOFD is promising for NDE of thick walled weldment (> 25 mm)
• Internationally TOFD has been used only for thicknesses > 12.5 mm and

limited success up to 10 mm

• IGCAR pioneered the application of TOFD combining it in a novel way

with immersion technique to NDE of 3.0 mm thick welds

Combined TOFD and immersion images of the side drilled holes (SDH) and notches in 10 mm, 5mm and 3 mm thick specimens respectively. A 5 MHz flat TOFD Probes with 45° angle (~10° probe tilt) with 15.0 mm Probe separation, ~8 mm water path and 65 dB gain was used. Arrows indicate the notches and SDH

Reactor Containment Building

Ring Beam

Impact echo testing for integrity assessment of ring beam of inner containment structure of Kaiga Atomic Power Plant

Mock-up studies Thickness: 1.2 -1.8 m Diameter: 42 m

Bureau of Indian Standard Prepared Exploring possibility for International standard

Without defect

Void of 200 mm dia at 500 mm depth

Intact Reinforced rod Delaminated Reinforced rod

f = CP /2d f = CP /4d f = CP /2d

Standardization of Impact Echo Testing

Test procedure developed for testing of thick concrete structures

Duct sheath in the ring beam Properly intact reinforced rod in the ring beam

A M P L I T U D E

Comprehensive Technology for In-service Inspection of PFBR Steam Generator Tubes – Modeling, Design, Fabrication, Instrumentation and Software for RFECT

Remote Field Eddy Current Test Instrument Developed In-house

50 100 150 200 250 300 1 2 3 4 5

10% WT 20% WT 40% WT 60% WT Remote Field Output, Volts Scan Distance, mm

Flexible probe with WC rings developed for negotiation of bends

Wavelet Signal (db-10) Raw Signal Bend region RFEC output, Volts Scan distance, mm

Wavelet Signal (db-10) Raw Signal 30% Defect Bend region RFEC output, Volts Scan distance, mm

Wavelet transform method for suppression of bend signals Enhanced performance with WC rings

20 30 40 50 60 70 80 90 100

• 0.01

0.00 0.01 0.02 0.03 0.04 0.05 0.06 0.07 0.08 0.09 0.10

9Cr-1Mo, 400 Hz Inter-coil distance 40 mm Pb Air WC

RFEC Signal Ampltidue, Volts Distance, mm

Technology successfully demonstrated in sodium test facility

Finite Element Modeling of RFEC Method

Near Field Zone Remote Field Zone

Aφ=0 Aφ=0 z

Solution domain

r

Descritised mesh Predicted Poynting vector plots of vector potential

Transition zone

50 100 150 200 250 300 350 400 450 500 550 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1

S can position, mm RFEC Amplitude, Volts

Model Experimental

1.9 2 2.1 2.2 2.3 2.4 2.5 2.6 2.7 2.8 0.2 0.4 0.6 0.8 1 1.2 1.4 1.6 1.8 2 x 10

• 5

Receiver coil location, ID (12.6 mm) times Induced voltage in the Receiver coil, Volts

700 Hz 900 Hz 1100 Hz 1300 Hz 1500 Hz 1100 Hz Experimental

FE Model Validation

Optimum Frequency: 1100 Hz Optimum Spacing: 42 mm (3 ID)

Opt Rec Loc

800 900 1000 1100 1200 1300 1400 1 2 3 4 5 x 10

• 6

Frequency, Hz RFEC Intensity, Volts

Transition Zone 10%WT 20%WT 30%WT 40%WT

Remote Field Zone

Finite Element Modeling of Bend Regions in Steam Generator Tubes - RFECT

9Cr-1Mo tube

Arrangement of Axial and Circumferential RFEC receiver coils for obtaining signals from localized flat-bottom holes of different depth

Model based optimisation of RFEC Sensors

Axial coil Circumferential coil

20% WL 1 mm dia. 60% WL 1 mm dia. 1 mm dia. Hole

Predicted RFEC signals due to a 20%, 60% wall loss flat bottom holes and a through hole of 1 mm dia. in SG tube

20% WL 1 mm dia. 60% WL 1 mm dia. 1 mm dia. Hole

Axial coil Circumferential coil

Quantitative analysis revealed that the axial pick-up coil has better detection sensitivity than the circumferential coil

Ultrasonic Method for qualification of in-service degradation & rejuvenation treatment of service exposed Inconel 625

NH3 cracker tubes in heavy water plants

• Solution annealed condition (~ 60 % elongation)

Service exposure: ~873 K for ~1,20,000 h

• Reduction in toughness (~5% elongation) due to Intermetallics

Reused after rejuvenation by resolution annealing (RSA) after ~1,20,000 h SE

Philosophical Magazine A, (2003)

1 10 100 1000 5820 5840 5860 5880 5900 5920

RSA SE

SE+923 K SE+1023 K SE+1123 K RSA+923 K RSA+1123 K

Ultrasonic longitudinal wave velocity, m/s

Time, h

Velocity increases with precipitation and decreases with dissolution

TOF thickness V × = 2

⎟ ⎟ ⎠ ⎞ ⎜ ⎜ ⎝ ⎛ − ⎟ ⎟ ⎠ ⎞ ⎜ ⎜ ⎝ ⎛ − ⎟ ⎟ ⎠ ⎞ ⎜ ⎜ ⎝ ⎛ = 1 2 2

2 2 L T L T

TOF TOF TOF TOF ν

Accuracy ~ ± 0.0006

Ultrasonic measurements can be used To monitor the degradation in mechanical properties To extend the life span of the tubes beyond 120000 lakh hours for rejuvenation To assess the rejuvenation heat treatment of the tubes

Poisson’s ratio and hardness for effective utilisation of Inconel 625 tubes in ammonia crackers of heavy water plants

Anish Kumar et al., J. Nucl. Mater., (2006)

150 200 250 300 350 0.2925 0.2950 0.2975 0.3000 0.3025 0.3050 0.3075 0.3100 0.3125 0.3150 0.3175 0.3200 0.3225

Poisson's ratio Hardness, VHN

Virgin V+747 h V+57194 h MC (~20000h) 120000 h (1-35) 120000 h (36-70) RSA RSA+23000 h Failed

0 .1 1 1 0 1 0 0 1 0 0 0 1 .8 2 1 .8 4 1 .8 6 1 .8 8 1 .9 0 1 .9 2 1 .9 4 1 .9 6 1 .9 8 2 .0 0 2 .0 2 2 .0 4 2 .0 6

A n n ealin g T em p eratu re = 1 0 7 3 K S tag e C S tag e B S tag e A

VL / VT A nnealing T im e, h

1 2 3 4 5 6 7 5 10 15 20 25

AISI type 316 SS

d, µm

28 40 63

FWHM, MHz PF, MHz d

• 1/2, mm
• 1/2

PF / FWHM, MHz

150 200 250 300 111 250 1000

Yield strength, MPa Yield stress, MPa

Ultrasonic spectral parameters for grain size measurements

400 500 600 700 800 900 1000 1100 180 182 184 186 188 190 192 194 196 198 200

Reference

Mean lifetime (ps) Annealing Temperature (K)

4810 273 523 773 1023 4790 4770 4750 4730 4710 225 200 175 250

TEMPERATURE, K ULTRASONIC VELOCITY, m/sec. HARDNESS, VHN 10 MHz 16 MHz 25 MHz VHN

Positron annihilation & ultrasonics for point defects and fine intermetallic precipitates in Zircaloy-2 Ultrasonics for monitoring reduction in dislocation density and recrysatllisation in cold worked D9 alloy

NDE for Point Defects, Dislocations and Grain size

2 4 6 8 10 12 14 16 18 20 22 24

• 0.5

0.0 0.5 1.0 1.5 2.0 2.5 3.0 3.5 4.0 4.5 5.0 5.5 6.0 6.5 7.0 7.5 8.0

H2 S3 R3 N1 L1 O3 I1 G2 J1 K1 M2 U3 T3 Q3 P3 B1 D2 C1 F2 E1 A1

Broken Macro-cracks Micro-fissures Not affected

Strauss tested specimens

EC Signal Amplitude, V Specimen Identification Number

2 4 6 8 10 12 14 16 18 20 22 24 0.0 0.1 0.2 0.3 0.4 0.5 0.6 0.7

H2 D2 C1 K1 L1 N1 J1 M2 G2 I1 O3 F2 E1 A1 U3 T3 S3 R3 Q3 P3 B1

Broken Macro-cracks Micro-fissures Not affected

As-aged specimens

EC Signal Amplitude, V Specimen Identification Number

Eddy Current Method for Sensitisation and Intergrannular Corrosion in 316 Stainless Steel

Not affected Micro-fissures Macro-cracks Broken

GMR Sensors for Deep-surface NDE

• 5

5 10 15 20 25 30 35 0.00 0.02 0.04 0.06 5 mm below surface 10 mm below surface

GMR Output, V Scan Distance, mm

Mild steel plate Thickness:20mm

Hall vs. GMR Hall: Large dynamic range GMR: High sensitivity for low magnetic fields 2DEG Micro-Hall sensor array developed in collaboration with Indian University

An integrated EC-GMR sensor has been developed for NDE of stainless steels

Giant Magneto-Resistance (GMR) effect

Fatigue crack in a stainless steel flange Before processing After processing

Eddy Current Imaging – Automated Inspection

Raster-scan Imaging Phased-array Imaging, IITM

Raster-scan Artificial neural network based intelligent imaging scheme developed for automated detection and sizing of defects

Automated imaging for stainless steels NDE

5 10 15 20 25 5 10 15 20 25 30 35 0.0 0.2 0.4 0.6 D e p t h , m m Y Axis, mm X Axis, mm

Application of imaging scheme to stainless steel weld having defects Eddy current image of a service induced fatigue crack in a stainless steel flange

This scheme has demonstrated reliable detection of defects as shallow as 0.2 mm deep and displayed three-dimensional pictures of defects with a ten-fold reduction in imaging time

Ultrasonic and eddy current based C-scan imaging

• f austenitic stainless steel weld profile to assist

remote in-service inspection

Eddy current image

Weld Base Metal

Ultrasonic amplitude image

• Ultrasonic amplitude

Ultrasonic amplitude – – based on texture and grain size based on texture and grain size (through thickness) (through thickness)

• Eddy current

Eddy current – – based on ferromagnetic based on ferromagnetic δ δ-

• ferrite (surface)

ferrite (surface)

200 400 600 800 1000

• 30
• 20
• 10

10 20 30

138µ 78µ 30µ

Amplitude, A.U. Time, ns

10 20 30 40 50 60 70 20 40 60 80 100 120

30µ 78µ 138µ Amplitude, A.U. Frequency, MHz

Ultrasonic spectral analysis for grain size measurement in AISI type 316 SS

αs=Sd3f4

⎟ ⎟ ⎠ ⎞ ⎜ ⎜ ⎝ ⎛ + ∝

5 5 3 2 2

2 2

T L L

V V V C S ρ

C = C11-2C44-C12

Characterization of Microstructural changes in materials and Grain size in 316 SS

10 20 30 40 50 60 2 4 6 8 10 12

30 µm 78 µm 138 µm

Amplitude, A.U. Frequency, MHz

20 40 60 10 20

• Mod. 9Cr-1Mo

ferritic steel

130μm 20μm

Amplitude, A.U. Frequency, MHz

10 20 30 40 10 20 30 40 50 60 70

P2 P1

130 µm 92 µm 20 µm

Amplitude, A.U. Frequency, MHz

10 20 30 40 5 10

AISI type 316 SS

138μm 78μ 30 μm

Amplitude, A.U. Frequency, MHz

1 2 3 4 5 6 7 5 10 15 20 25

A ISI type 316 SS

d, µm

28 40 63

FW HM , M Hz PF, M Hz d

• 1/2, m

m

• 1/2

PF / FWHM, MHz

150 200 250 300 111 250 1000

Yield strength, MPa Yield stress, M Pa

1000 1100 1200 1300 1400 1500 1600 1700 0.4 0.6 0.8 1.0 1.2 1.4 1.6 1.8

α+m+C α+C

m+δ m m+C

Soaking tem perature, K Spectral peak ratio (P1 / P2)

Spectral peak ratio

20 40 60 80 100 120 140

20 MHz Transducer

Grain size, µm

Grain size

Grain size measurement in AISI type 316 SS Grain size measurement in mod.9Cr-1Mo ferritic steel

Structured Approach to Asset Management

Asset Management Design Objectives

Materials and Materials and Pre Pre-

• service Data

service Data (Fabrication, (Fabrication, Machining,Welding Machining,Welding Qualification, etc) Qualification, etc)

Repairs and In-service Data International Experiences Knowledge Knowledge Base Base Decision Decision Making Making Knowledge Base can be Knowledge Base can be created for each created for each component of PFBR component of PFBR

Developed for NDE & Visual Inspection

• f PFBR Steam

generator tube. Compact design (Dia 260 mm / ht 177 mm / w t 25 kg. ± 0.5 mm probe position accuracy Inspection velocity 200 mm per sec.

ROBOTI C DEVI CE FOR I NSPECTI ON OF PFBR STEAM GENERATOR ROBOTI C DEVI CE FOR I NSPECTI ON OF PFBR STEAM GENERATOR

PHOTOGRAPH OF 4-LEGGED WALKING ROBOT

4-LEGGED WALKING ROBOT ON MOCKUP SG TUBE SHEET CAD MODEL OF CABLE WINCH WITH CABLE ROUTER DETAIL OF CABLE WINCH

Human Resources Development

• Training School (50 years)
• Research Fellows for Ph. D
• Dr. K.S. Krishnan Fellowship
• Homi Bhabha National Institute
• Board of Research in Nuclear Sciences
• Collaborations with Academic and R&D

Organisations

• Continuing Education Programme
• Training and Certification Programme
• Setting up Centres of Excellence in Academic

Institutes

• Student Curriculum Projects

Robust NDE Technologies

CORE INDUSTRIES DEFENCE ART SPACE HRD MEDICAL

Spin-offs ……..

NDE Technology for Space Application NDE Technology for Space Application

Detection of cracks in Detection of cracks in maraging maraging steel steel weldments weldments by UT and by UT and advanced signal processing advanced signal processing methods methods Pyros indispensable to any space Pyros indispensable to any space craft craft – – PSLV, GSLV, Satellites PSLV, GSLV, Satellites Most critical and one shot devices. Most critical and one shot devices. Pyros Pyros such as cable cutters and such as cable cutters and initiators examined by neutron initiators examined by neutron radiography using KAMINI national radiography using KAMINI national facility. facility.

Excellent example of team work between Excellent example of team work between two institutions IGCAR two institutions IGCAR-

• ISRO and

ISRO and utilisation of national facility for national utilisation of national facility for national cause. cause.

Neutron radiography of a Pyro Charge Charge O rings O rings

Fingerprinting methodology established for metallic bronzes

Documentation

Lost wax process and scientific methods elucidated in simple language in Monograph Where Gods Come Alive

• Book by Baldev Raj et al.

Characterisation & Conservation of South Indian Bronzes

Identification and Application of NDE methods for characterising metallic art

• bjects (south Indian bronzes)

(DST-IGCAR-Govt. Museum) Experimental investigation on more than 200 rare bronzes at Chennai museum (NDE methods high precision digital photography, radiography, X-ray fluorescence and In- situ metallography)

Typical digitised radiographic image of Vishnu icon showing porosities in the hand

Ardhanareswarar 11th century

Characterisation and Conservation of South Indian Bronzes

The Delhi Iron Pillar

FEATURES OF THE DELHI IRON PILLAR TOTAL LENGTH : 23 Ft 8 In. ABOVE GROUND LEVEL : 22 Ft BELOW GROUND LEVEL : 20 In. Upper Dia. (BELOW DECORATION) : 12.5 INCHES LOWER DIAMETER : 16.5 INCHES TOTAL WEIGHT : 6 TONS THE ORNAMENTAL TOP, THE BASE AND THE EXACTNESS OF THE SCOPE NEED SPECIAL MENTION

The Delhi Iron Pillar

Microstructure

• f Main body

(4.88m) smaller grains with pointed slag within

200 μm

Radiograph showing presence of elongated voids detected in the top region at 0.45M below the capital. Impact echo signal

• btained at 70 mm

below the top of the cylindrical portion of Delhi Iron Pillar showing a defect at about 60 mm depth (void detected by radiography)

Clinical Diagnostics and Healthcare Clinical Diagnostics and Healthcare – – Infrared Infrared Thermography Thermography Technique Technique

Thermal Imaging techniques Thermal Imaging techniques explored in collaboration with explored in collaboration with hospitals for hospitals for

• non

non-

• invasive Detection of

invasive Detection of vascular disorders vascular disorders (left deep (left deep vein thrombosis condition is vein thrombosis condition is indicated) indicated)

• early Detection of cancers

early Detection of cancers

NDE is inseparable part of modern human civilization and contributes to better quality of life on the earth