Academic literature on the topic 'Dye penetrant inspection'
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Journal articles on the topic "Dye penetrant inspection"
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Abend, Klaus. "Fully automated dye-penetrant inspection of automotive parts." Computer Standards & Interfaces 21, no. 2 (June 1999): 157. http://dx.doi.org/10.1016/s0920-5489(99)92144-x.
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Cicic, Dumitru Titi, Cătălin Gheorghe Amza, Diana Popescu, and Florea Dorel Anania. "Automated Stand for Non-Destructive Testing Evaluation of Metal Products." Applied Mechanics and Materials 371 (August 2013): 401–5. http://dx.doi.org/10.4028/www.scientific.net/amm.371.401.
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Problem be used for evaluating products quality: - Destructive evaluation, in which the product is destroyed in order to analyse its properties and internal structure; - Non destructive evaluation (NDE), used for identifying defect and irregularities, without damaging the product. These non destructive evaluation methods include [1-4]: ‐ Visual and optical testing – VT; ‐ Magnetic particle testing – MT; ‐ Liquid penetrant testing –PT; ‐ Radiographic testing – RT ; ‐ Ultrasounds testing – UT; ‐ Eddy current testing – ET; One of the most frequently used method of non destructive examination is PT or dye penetrant testing (DPT), due to the low costs involved, ease of use and flexibility, suitability to a large number of applications. This method evaluates the presence of open discontinuities (or cracks) on the surface part, based on reverse capillary action and on the developer absorption effect which draw out penetrant and produces indications visible for the inspector (see fig.1 for a principle scheme of LP examination [5]). Although widely used, PT has several disadvantages: - Limitation to surface defects or to the defects which communicates with the surface; - Only products with non porous surfaces (or with low porosity) can be inspected; - Important amount of time used for manipulating the parts during inspection; - Results interpretation heavily depends on subjective aspects such as operator experience, knowledge and motivation. In order to eliminate or reduce the operator involvement in the process steps, research has being made for automating the process, such examples of liquid penetrant inspection lines can be found in [10-15]. However, in all analysed automated PT systems, the inspection is still made visually by an inspector, who gives a pass/fail grade for the inspected parts. The difficulty of fully automating the liquid penetrant inspection process is due not only to the necessity to precisely determine and control process parameters (dwell time, developer time, drying time, quantity of penetrant, developer and cleaning water, pressure for spraying solutions with penetrant, developer and cleaning water, transport speed, etc.) but also to the evaluation and results interpretation process. Thus, even if there are patents [16-17] which present approaches and general frameworks for fully-automated LPT systems, including also automatic image processing of the flaws, to the best of the authors’ knowledge, these equipment are not yet implemented. In this context, this paper presents an experimental stand for a fully automated liquid penetrant inspection line, which includes the development and use of dedicated imaging software used for real time interpretation of the images acquired using a digital camera. The novelty of the research consist in designing and building a fully-automated LPT stand, controlled by a soft which contains also a module for acquisition and image processing in real time without no human implication.
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Wari, Alan, Hendri Nurdin, and Kyaw Zay Ya. "Porosity Defect Analysis in ST 37 Steel Welding Joints Using the Dye Penetrant Method." Teknomekanik 3, no. 1 (May 25, 2020): 1–8. http://dx.doi.org/10.24036/tm.v3i1.5272.
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The procedures in the world of welding all look simple, but all welding that looks simple must have extensive knowledge in accordance with the definition of welding. This welding is a permanent connection technique, when the welding process takes place the results do not always meet the quality standards that have been determined. The cause of the welding results that do not meet the quality standards in the form of dirt on the material when before welding and so forth. The purpose of this study is that the specimen specimens are accepted according to the welding institute's standard acceptance criteria (TWI) This research uses st 37 steel by using SMAW welding electrodes LB 52U (E 7016) diameter 2.6mm for root, and LB 52U (E 7016) diameter 3.2 for fillers and caping with welding position 1G. Testing of welding results is carried out by the non destructive test of the dye penetrant method whose inspection results are determined based on the standard ASME. The results of this test study discontinuity in the form of porosity on the surface of the welding results in specimen 1, namely material contaminated by dirt, there are porosity defects scattered with a length of 6mm and porosity of 10mm so based on the standard TWI both test specimens were declared rejected, and in specimen 2, material that was not contaminated with impurities, there were porosity defects of 2mm and 2.5mm so that according to the standards of the two specimens the test was accepted. For the results of welding defects that are rejected can still be corrected by linking to the defects that, and can be done welding again.
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Ward, C. "The use of eddy current arrays as a replacement for dye-penetrant inspection of generator and exciter end-rings." Insight - Non-Destructive Testing and Condition Monitoring 47, no. 9 (September 1, 2005): 543–46. http://dx.doi.org/10.1784/insi.2005.47.9.543.
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DE BONI, Luis Alcides Brandini, and Jackson CAMANA. "REMOVAL OF DYE AND WATER RECYCLING FROM THE WASTEWATER OF THE LIQUID PENETRANT INSPECTION THROUGH THE ELECTROCOAGULATION AND THE FENTON REACTION." Periódico Tchê Química 12, no. 24 (August 20, 2014): 79–84. http://dx.doi.org/10.52571/ptq.v11.n22.2014.79_periodico_22_pgs_79_84.pdf.
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This paper describes the procedures used in the company Micromazza PMP to undertake the effluent treatment of the test by liquid penetrant inspection (LPI) used for the detection of cracks and micro cracks invisible to the naked eye in metallic products. It was used the Fenton reaction combined with electrocoagulation process to replace the impurities removal system with activated carbon. After the decontamination of the wastewater, the sludge was removed dehydrated and led to the landfill. The recovered water was odorless and colorless. The improvement in some quality standards analyzed as true color, COD and turbidity , was 99.36 % , 88.98 % and 99.34%, respectively. Due to the use of iron electrodes for the realization of the electrocoagulation process, a 15% increase in iron concentration in the effluent happened, howevert his does not exceeded the quality standards defined in CONAMA Resolution No. 430/2011.The results demonstrate that the process was efficient for the decontamination of wastewater arising from this quality control test (LPI).
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Thomas, Joby V., K. Thomas Tharian, C. R. Anoop, and P. Chakravarthy. "Influence of Filler Wire Material on Dissimilar Welding of 15-5PH to KC20WN (Haynes 25)." Materials Science Forum 830-831 (September 2015): 298–301. http://dx.doi.org/10.4028/www.scientific.net/msf.830-831.298.
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Many of the components/assemblies used in strategic sectors involve dissimilar metal weld joints and dissimilar welding has always imposed challenges in terms of the weld quality because of the physical and chemical mismatches of the base metals. In the present study, dissimilar welding of stainless steel 15-5PH (UNS S15500) to a Cobalt-base super alloy KC20WN (UNS R30605/ Haynes 25) is attempted for specific purpose in space applications. Gas Tungsten Arc Welding is carried out with two types of filler wires, viz., KC20WN and ER 630 (17-4PH). Visual inspection, Dye Penetrant testing and X-ray radiography testing revealed defect free joints and the joints were also characterized for microstructure. Superior properties were observed when welding was carried out with KC20WN filler wire compared to that with ER630 filler wire.
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Rajole, S., P. R. Sondar, S. Hiremath, and K. S. Ravishankar. "Failure Analysis of Industrial Discharge Hopper Pipe." Journal of Modern Manufacturing Systems and Technology 5, no. 1 (November 16, 2020): 1–6. http://dx.doi.org/10.15282/jmmst.v5i1.5149.
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This work presents the detailed investigation and root cause analysis of catastrophic failure of an industrial discharge hopper pipe. The hopper pipe investigated in the present work is made of austenitic stainless steel, 316 grade, a commonly used grade for valves, pipes and heat exchanger tubes. The pipe fractured in transverse direction, leading to the failure of discharge pipe. Visual inspection, dye penetrant test, chemical analysis, microstructural analysis, and fractography analysis were carried out on the failed part and it was concluded that stress corrosion cracking led to the failure of hopper pipe. The pipe constantly being under the exposure of industrial water and the presence of chlorine content in it made it susceptible for stress corrosion cracking. Transgranular fracture was clearly observed in the microstructure of failed sample and spot EDX at the fracture location confirmed the presence of chlorine content. Further, fractography showed striations indicating fatigue loading. The work concluded that stress corrosion cracking as the root cause of failure.
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Santella, Michael, X. Frank Chen, Philip Maziasz, Jason Rausch, and Jonathan Salkin. "Properties of a thick-section narrow-gap gas tungsten arc weld of cast Haynes 282." Welding in the World 65, no. 5 (January 28, 2021): 961–71. http://dx.doi.org/10.1007/s40194-021-01077-4.
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AbstractA 50.8-mm-deep gas tungsten arc weld was made with matching filler metal in cast Haynes 282 alloy. The narrow-gap joint was filled with 104 weld beads. Visual and dye-penetrant inspection of cross-weld specimens indicated that the cast base metal contained numerous casting defects. No visible indications of physical defects were found in the weld deposit. The weld heat-affected zone was characterized by microcracking and localized recrystallization. The cause of the cracking could not be determined. Hardness testing showed that a softened region in the as-welded heat-affected zone was nearly eliminated by post-weld heat treatment. Tensile testing up to 816 °C showed that cross-weld specimen strengths ranged from 57 to 79% of the cast base metal tensile strength. The stress-rupture strengths of cross-weld specimens are within 20% of base metal reference data. Failures of both tensile and stress-rupture specimens occurred in the base metal.
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Vukelic, Goran. "Assessment of a Boat Fractured Steering Wheel." Polish Maritime Research 23, no. 3 (September 1, 2016): 91–96. http://dx.doi.org/10.1515/pomr-2016-0037.
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Abstract During regular use of the steering wheel mounted on a boat, two cracks emanating from a fastener hole were noticed which, consequently, caused final fracture of the wheel. To determine the behavior of a boat steering wheel with cracks present, assessment of a fractured wheel was performed. Torque moments of the fasteners were measured prior to removing the steering wheel from the boat. Visual and dye penetrant inspection followed along with the material detection. Besides using experimental procedures, assessment of the fractured wheel was performed using finite element analysis, i.e. stress intensity factor values were numerically determined. Variation of stress intensity factor with crack length is presented. Possible causes of crack occurrence are given and they include excessive values of fastener torque moments coupled with fretting between fastener and fastener hole that was poorly machined. Results obtained by this assessment can be taken for predicting fracture behavior of a cracked steering wheel and as a reference in the design, mounting and exploitation process of steering wheels improving that way their safety in transportation environment.
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Negi, B. S. "Case Studies on Field Repairs of Stainless Steel Components in Refinery." Advanced Materials Research 794 (September 2013): 375–79. http://dx.doi.org/10.4028/www.scientific.net/amr.794.375.
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Stainless steels (SS) possess excellent corrosion, creep and high temperature oxidation resistance and are invariably used in refinery for construction of heater tubes, tube supports, Heat exchanger bundles, piping and internal lining of pressure vessels. Ferritic stainless steel type 405 is used for column strip-lining, martensitic stainless steel type 410 is used for column trays and heater tubes and austenitic stainless steel family is used very extensively for lining, piping, heat exchanger, heater tubes and tube supports. On-stream and turnaround condition monitoring of plant and equipment are carried out for health assessment and mitigation of premature failure. However, catastrophic failures of stainless steel due to stress corrosion cracking, thermal fatigue and stress relaxation cracking are encountered in addition to bulging and cracking of strip-lining. Field repairs of these components are required to be done. Stainless steels are difficult to weld due to low thermal conductivity, higher coefficient of thermal expansion, fissuring and solidification cracking problem during welding. Lower heat input and fast cooling facilitate the welding process. Welding of service exposed stainless steels is more challenging, as it has already undergone metallurgical degradation. Welding of stainless steels is carried out using TIG and SMAW process with matching electrode after establishing the welding specification procedures and welders qualification. Field repairs of stainless steels components are also attempted with original procedures and in case of difficulties, a buttering layer of inconel (ERNiCr3) or ER 309Mo is provided on the welding surface before using matching electrodes. Quality assurance of weld joint is ensured by stage-wise inspection and non-destructive testing. Dye penetrant test of root run and radiographic examination of final weld joint are most common. Post weld heat treatment is done as per code requirement. This Paper highlights three case studies on field repairs of stainless steel components in refinery. 1. Welding procedure followed for repair of bulged and cracked SS 316 strip-lining and cladding on carbon steel backing material. It is a dissimilar welding of SS 316L with degraded carbon steel. 2. Field welding of SS 347 Piping components, which has undergone thermal relaxation cracking at fillet joints. 3. Welding repair of SS 310 cast heater tube support conforming to A 297 Gr HK 40. The Paper also presents brief failure analysis with reasons and remedies.
Dissertations / Theses on the topic "Dye penetrant inspection"
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Vuksanovic, Aleksander, and Marko Gajic. "Implementation av underhållsstrategi på ett vattenreningsverk : Underhåll av svamp- och bakterietankar." Thesis, KTH, Hållbar produktionsutveckling (ML), 2020. http://urn.kb.se/resolve?urn=urn:nbn:se:kth:diva-276688.
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Idag finns det inte tillräckligt underhåll på de 15 svamp- och bakterietankar som finns på AstraZenecas vattenreningsverk i Gärtuna, Södertälje. Företaget använder sig av avhjälpande underhåll där de väntar på att tankarna ska gå sönder för att sedan laga dem. Reningsverket vill skapa en underhållsstrategi på tankarna genom att ta reda på om livslängden kan förlängas eller om, och i så fall när, utrustningen behöver renoveras, uppgraderas eller bytas ut. I litteraturstudier undersöktes underhållsstrategier, vattenreningsverk och olika tillståndskontroller. Besök gjordes för att få en bättre uppfattning om hur arbetet på vattenreningsverket ser ut idag. Intervjuer hölls med chefen för vattenreningsverket, en erfaren drifttekniker samt två externa företag som jobbar med underhåll. I resultatet framgår information om vilka fel som uppstått, vilka åtgärder som vidtagits samt vad det kostat. Det framgår även hur underhåll kan ske med olika externa parter och kostnader för detta. Två olika tillståndskontroller, digital röntgenskanning och penetrantprovning föreslås för att upptäcka fel på tankarna. Efter analys av resultatet har slutsatser om en ny underhållsstrategi kunnat dras. Rekommendationer om hur den kan implementeras och lämpligt intervall har tagits fram. AstraZeneca föreslås gå från ett avhjälpande till ett schemalagt tillståndsbaserat underhåll, där tillståndskontroller utförs var tredje, fjärde eller femte år beroende på personalens bedömning och de rekommenderas också att använda sig av externa resurser när det kommer till tvättning och tillståndskontroller av tankarna. Avhjälpande underhåll är omöjligt att planera och kommer med vår lösning att minimeras. Schemalagt tillståndsbaserat underhåll som vi rekommenderar kommer resultera i en mycket enklare planering och oväntade kostnader likväl som oväntade stopptider kommer undvikas. Regelbundet underhåll kommer troligtvis resultera i att tankarnas livslängd ökar vilket bidrar till en bättre hållbarhet och man slipper köpa in nya tankar.Today, there is not enough maintenance on the 15 fungal and bacterial tanks found at AstraZeneca's wastewater treatment plant in Gärtuna, Södertälje. The company uses a maintenance strategy where they wait for the tanks to fail and then fix them. The treatment plant wants to create a maintenance strategy for the tanks by finding out if the life span can be extended or if, and if so, when the equipment needs to be renovated, upgraded, or replaced. With literature studies maintenance strategies, wastewater treatment plants and various condition investigations, were analysed. The visits were made to get a better idea of how the work at the wastewater treatment plant looks like today. Interviews were held with the head of the water treatment plant, an experienced operating technician and two external companies working on maintenance. The result shows information about what errors occurred, what measures were taken and what it cost. It also shows how maintenance can be done with various external sources and costs for this. Two different condition investigations, digital x-ray scanning and penetrant testing are suggested to detect errors in the tanks. After analysing the results, conclusions about a new maintenance strategy could be drawn. Recommendations on how it can be implemented, and an appropriate interval have been developed. AstraZeneca should go from corrective to scheduled condition-based maintenance, where condition investigations are performed every three, four or five years depending on the staff's assessment and they could make use of external sources when it comes to washing and condition investigations of the tanks. Corrective maintenance is impossible to plan and our solution will minimize this. Scheduled condition-based maintenance that we recommend will result in a much simpler planning where unexpected costs as well as unexpected downtime will be avoided. Regular maintenance will probably result in an increase in the service life of the tanks, which contributes to better durability and they will not have to buy new tanks.
Book chapters on the topic "Dye penetrant inspection"
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Moore, T. D., and A. Starr. "Development of an Automated Fluorescent Dye Penetrant Inspection System." In Condition Monitoring and Diagnostic Engineering Management, 599–608. Elsevier, 2001. http://dx.doi.org/10.1016/b978-008044036-1/50071-8.
Full textConference papers on the topic "Dye penetrant inspection"
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Abend, Klaus. "Fully Automated Dye-Penetrant Inspection of Automotive Parts." In International Congress & Exposition. 400 Commonwealth Drive, Warrendale, PA, United States: SAE International, 1998. http://dx.doi.org/10.4271/980739.
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RUSSELL, D., and J. KEREMES. "Probabilistic simulation for flaw acceptance by dye-penetrant inspection." In 31st Structures, Structural Dynamics and Materials Conference. Reston, Virigina: American Institute of Aeronautics and Astronautics, 1990. http://dx.doi.org/10.2514/6.1990-1013.
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Nail, Carl. "A Novel Technique for Determining the Location of a Hermetic Leak in a ‘Metal Can’ (TO-x) Package." In ISTFA 2007. ASM International, 2007. http://dx.doi.org/10.31399/asm.cp.istfa2007p0231.
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Abstract Root-cause analysis of hermetic leak failures is complicated by the difficulty in isolating the leak location. Standard dye penetrant inspection is not consistently successful. The addition of pressure to the dye penetrant, followed by metallographic mounting and preparation, and subsequently followed by vacuum storage, greatly enhances the visibility of the dye and more effectively decorates the leak location.
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Noteboom, Jan Willem. "Generator Retaining Rings: In Situ Inspection and Life Assessment." In ASME 2009 Power Conference. ASMEDC, 2009. http://dx.doi.org/10.1115/power2009-81072.
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Stress corrosion cracking (SCC) in retaining rings of generators has been a major issue since large generator manufactures started to advise generator owners to replace and inspect retaining rings made from certain materials in the mid 1990’s. KEMA has been inspecting generator retaining rings with automated systems from the seventies on. Since 1995 new developments led to the possibility of also testing rings in situ, eliminating the need of removing the rotor from the stator and thus saving considerable down-time. Over the years, step by step improvements to the system and its application to generator retaining ring inspections have been implemented, one of which is the use of smaller probes and manipulators. Another improvement is the implementation of eddy current testing (ECT) to increase the detection capability for cracking at the outside surface in parallel to the automated ultrasonic testing (AUT). Experience obtained with this method contradicts some of the common ideas about reliability of other Non-destructive testing (NDT) methods, in particular the application of Dye Penetrant inspection (DPI) which appears to be less reliable. By performing fracture mechanics calculations to evaluate detected and sized flaw indications, predictions of remaining life of the rings can be made (Fitness-for-Purpose analysis). This paper presents results of applying the in situ retaining ring inspection system in the last 14 years and gives an overview of cases — some of those from recent inspections — where defect indications were detected, sized and evaluated. In some cases this resulted in recommendations to replace the retaining rings.
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Tittmann, B. R., and S. Jayaraman. "Locomotive Wheel Inspection With EMAT Technology." In ASME/JSME 2004 Pressure Vessels and Piping Conference. ASMEDC, 2004. http://dx.doi.org/10.1115/pvp2004-2833.
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There is a need to analyze locomotive wheels for flank cracks in a non-destructive manner in order to prevent catastrophic failures. Flaw, shape, and size are desired parameters in establishing the quality of commercial tires. A variety of defects such as voids, inclusions, surface and internal cracks, or the like, must be discerned in order to prevent failure. This paper exhibits and compares the benefits of a number of different techniques used for flaw detection. Non-destructive evaluation (NDE) techniques used are magnetic particle inspection, dye penetrant, eddy current, electro-magnetic acoustic transducer (EMAT). The techniques vary in their ability to ascertain the flaw characteristics. Using a non-contact sensor such as the EMAT, to scan the wheels in an automated manner offers greater inspection speed at lower manpower. This paper reviews the basic concept of EMATs, introduces a recently developed technique for simulating EMAT performance by Finite Element calculation and features bench top results of waveform acquisition and signal-to-noise ratio dependence on lift-off. Next presented are calibration results for spark-eroded flaws in wheel sections for a variety of locations and sizes. Finally data are on flaw detection in a railroad service facility on several locomotives with wheels spinning at speeds up to 40 meters/minute. Results for both artificial and actual flaws are shown.
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Brumovsky, Milan, and Milos Kytka. "Monitoring Degradation in Nuclear Reactors." In ASME 2015 Pressure Vessels and Piping Conference. American Society of Mechanical Engineers, 2015. http://dx.doi.org/10.1115/pvp2015-45511.
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Nuclear reactor materials are affected by many stressors during their operation that result either from the nuclear reactions in the reactor core or by operation conditions (temperature, pressure) and water environment. Generally, several different methods of monitoring damage in reactor materials are applied, depending on their type, design and conditions: - Destructive, usually represent by surveillance specimens, - Semi-destructive, usually performed by cutting small specimens from component surface, e.g. for small punch tests, - Non-destructive, representing by non-destructive inspection methods applied during in-service inspections, like traditional ultrasonics, optical, dye-penetrant, eddy current etc. and also some new like automated ball indentation, thermoelectric power measurements etc. The paper summarizes the possibility of application of these methods on main reactor components and shows some typical results and problems.
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Hull, Scott M. "Nondestructive Detection of Cracks in Ceramics Using Vicinal Illumination." In ISTFA 1999. ASM International, 1999. http://dx.doi.org/10.31399/asm.cp.istfa1999p0217.
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Abstract Cracks and other defects in ceramic materials can be difficult or impossible to examine and photograph due to the extreme lack of contrast. A method for inspecting translucent ceramics using scattered light, also known as vicinal illumination, will be described. This method has been known in the ceramics industry for quite some time, but is not well known in the testing and failure analysis community. Electronics applications include substrates, packages, multilayer capacitors, and thin film resistors. Ceramic materials are used in electronic applications as microcircuit packages and substrates which carry signals and power between microcircuits. Fine cracks in ceramic materials can result in mechanical failures, electrical failures, and loss of hermeticity. Often, fine cracks are difficult or impossible to detect using standard nondestructive inspection techniques such as visual inspection, ultrasonic inspection, or vapor crack detection. Dye penetrant inspection is usually effective, but contaminates the part, which is unacceptable for space flight hardware. One effective nondestructive inspection method of detecting cracks involves examining the way in which light scatters through the ceramic material when viewed with a standard bright field reflected light microscope. This method, termed vicinal illumination, has been used for detecting cracks during failure analyses of several part types, and screening of space flight hardware. The technique has proven effective on several different types of ceramic materials as well. A related method for use with dark field equipment has also been used to successfully locate otherwise invisible cracks.
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Pathak, Dilip Parth, Kishore Padmanabha, Robert Joseph Wilhelmi, Luiz Henrique Velloso Coutinho, and Venkata Rao Brahmaji Vampati Veera. "Development of Design Criteria and NDE Method for HPHT Equipment." In Offshore Technology Conference. OTC, 2021. http://dx.doi.org/10.4043/31109-ms.
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Abstract Subsea production systems have been using API-specified methods and detection criteria for nondestructive examination (NDE) for equipment up to 15,000-psi rated working pressure. With higher pressure requirements and use of methods for evaluation of the fatigue life of HPHT equipment, existing criteria cannot be sufficient to achieve the desired fatigue life. This paper demonstrates more stringent design criteria and a detection method that was developed to achieve HPHT fatigue life, yet is cost and schedule effective. When fracture mechanics was used for fatigue life estimation, an initial flaw size is stated as a starting point in determining design life. Using API-specified NDE criteria of 1/16-inch detection of surface flaw, project design life was not achieved for certain components without a major redesign and retest. Smaller flaw lengths were preferred in critical areas instead of standard flaw sizes. This created a need for a high-sensitivity penetrant inspection technique to effectively detect this new minimum flaw size in critical areas. Various methods of NDE were considered, and a conclusion was taken in selecting the best inspection method. Fracture mechanics and finite element analysis required a minimum detectable flaw size length of 1/32 inch to meet the project design life without changing equipment technology. By using surface NDE with fluorescent liquid dye penetrant of sensitivity levels 2 and 3, all seeded flaws of 1/32-inch were consistently detected in the validation test coupon, which enabled the use of this stricter criteria for the analysis. Detailed procedures were established, and validation testing results were documented with photographs of detected flaws. Seeded flaw coupons were manufactured for validation of procedures and to train the various facilities that will use these techniques for production equipment. Additionally, procedures and guidelines were provided to inspectors and inspection facilities to ensure proper implementation of the methods. Measurement system analysis for repeatability and reproducibility was conducted at the facilities. This enabled the fatigue design of the HPHT equipment to advance beyond the boundaries of traditional methods and acceptance criteria set by current industry standards. New and tighter acceptance criteria were developed to improve HPHT fatigue life. High-sensitivity penetrant inspection technique, capable of detecting flaw sizes as small as 1/32-inch, was established and implemented. This inspection technique is not common to the oil and gas industry because of the ability of standard methods to readily detect the API-required criteria. The method has improved detection capabilities and has the potential to move toward adopting advanced design methods to address HPHT requirements.
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Brady, Brian G. "Cracking During the Installation of Interference Fit Fasteners and Bucked Rivets in 7050-T7XXX Machined Aluminum Parts." In ASME 2006 International Mechanical Engineering Congress and Exposition. ASMEDC, 2006. http://dx.doi.org/10.1115/imece2006-14815.
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This test program evaluated the effect of the installation of solid rivets and interference fit Hi-Tigue bolts on machined 7050 longerons (HiTigue is a registered trademark of the Hi-Shear Corporation of Torrance, (CA). Two simulated longeron specimens were machined from both 7050-T7451 and 7050-T7651 plate. Titanium Hi-Tigues and solid aluminum and Monel rivets were then installed with a pneumatic riveting hammer in sections of various thicknesses in the four machined longeron specimens. After all fasteners were installed, each fastener was subjected to a simulated mishap by applying the pneumatic riveting hammer to the installed fastener without support from an underlying bucking bar. Dye penetrant inspections to detect cracks were performed after the fastener installations and simulated mishaps. All fasteners were then removed and the open holes subjected to eddy current inspection. Visual observations concerning deformation of the machined longeron specimens during fastener installations and simulated mishaps were recorded. Cracking was noted in 0.063 inch thick longeron sections, compelling additional testing involving Hi-Tigues. Recommendations concerning the use of Hi-Tigues and solid rivets in 7050-T7XXX machined parts were made based on the results of the testing.
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Dalal, Mitul, Jorge Penso, Dave Dewees, and Robert Brown. "Longitudinal Seam Welded Piping Assessment in Refinery Reformer Units." In ASME 2019 Pressure Vessels & Piping Conference. American Society of Mechanical Engineers, 2019. http://dx.doi.org/10.1115/pvp2019-93706.
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Abstract Creep is progressive deformation of material over an extended period when exposed to elevated temperature and stresses below the yield strength. Poor Creep ductility and cracking can be a problem above 900 °F (482°C) in the HAZ of low alloy (Cr-Mo) steel. High stress areas, including supports, hangers and fittings are more vulnerable to cracking. Creep cracking has occurred in longitudinal pipe welds with excessive peaking or welds with poor quality. Numerous incidents of cracking in low alloy (Cr-Mo) steel have been reported in the power industry and in refineries with major concern in longitudinal seam welds as well as highly stressed welds in reactors-heaters interconnecting piping. This paper presents the results of an assessment performed on reactors-heaters interconnecting piping in a catalytic reformer unit with a maximum operating temperature of about 950 °F (510 °C) at 250 psig (1.7 MPa) (> 40 years in-service). Comprehensive inspection including visual, dye penetrant testing, thickness measurements and peaking measurements have been performed. Phased Array Ultrasonic Testing (PAUT) was utilized to detect crack-like defects and flaws. Detailed pipe stress analysis and finite element analyses (FEA) were also performed.