Transcript Inspectie van weerstandlassen met de Mini Scanner

AMSTERDAM
TECHNOLOGY
NDT Scan Solutions
Introduction
spot- and projection weld
inspection
with the
Mini Scanner
A high level inspection method with a handy instrument
AMSTERDAM
TECHNOLOGY
Raised in 2006 by:
• vAmsterdam SES
Software, Engineering and Systems for
ultrasonic and Eddy Current inspection
machines
• Technolothgy BV
Engineering of special machines and
instruments for Non Destructive Technology
Overview of build
immersion tank based
inspection machines
Ultrasonic
Immersion tank
scanners
•High resolution
•Complex shaped
products
•Focused transducers
Ultrasonic immersion tank scanner
A high quality inspection method
Practical inconveniences
•Static position: The samples have to be transported to the scanner
•The samples have to drown into the water
•Limited tank dimensions
•Time-consuming positioning of parts in the tank
•Long inspection times
•High investments
Project with DaimlerChrysler
Project description:
Design a portable ultrasonic scanner for spot weld inspection on location.
Specifications:
•Short inspection time
•No immersion of the inspected parts
•High resolution C-scan presentation
•For plate thickness from 0,5 mm
•Handheld instrument
Mini Scanner
A miniature “immersion tank” scanner.
The scanner head is filled with water
and is sealed with a membrane.
Gel is used as an ultrasonic couplant.
•Scan area: 10 x 20 mm
•Resolution: 0,1 x 0,1 mm
•Scan time: < 5 seconds
Diagram spot weld testing with the Mini Scanner
Red gate; sets the start
position of the yellow gate
Yellow gate; In this area the maximum
amplitude of the ultrasonic signal is measured
Moving
ultrasonic
transducer
Couplant
( gel )
A color related to
the value of the
maximal amplitude
in the yellow gate,
is set as a pixel in
the C-scan for each
scan point.
Water
chamber
Mini
Scanner
IE WE BE
IE=Interface Echo
A-scan
presentation
WE=Weld Echo
BE=Back Wall Echo
The C-scan is picture, composed by the 100 x 200 colored pixels
as generated in each scan point.
C-scan presentation
® Patent pending / all rights by Amsterdam Technology bv
Scanning method
•Focused ultrasonic transducer
moves in a water filled compartment
in the scanner head
•35MHz ultrasonic transducer
•Diameter focus point < 0,1mm
•Membrane sealed water chamber
•Spiral shaped scanning pattern
•High scanning speed
•Gel as ultrasonic couplant
® Patent
pending
Exchangeable
scan heads
Straight scan head for
perpendicular scanner
position.
Mirror based scan head for
angles scanner position.
Used for difficult to reached
spot weld position
Mini Scanner
System
Scanner with control
unit
•PC platform
•Windows XP
•Touch Screen
•USB data exchange
Spot weld test
High tension steel plate
Test parameters:
•Shape of the spot
weld nugget
•Shape of the pore
A-scan on cursor
position
- besides the weld -
Plate thickness first plate
In the yellow gate: back wall echo of the first plate
Spot weld test
High tension steel plate
Test parameter:
•Thickness of the
spot weld
A-scan on cursor
position
- in the nugget -
Thickness
In the yellow gate: No weld echo (good welded in that position)
In green gate: Back wall echo of the spot weld
Spot weld test
High tension steel plate
Test parameters:
•Size of the pore
•Depth of the pore
A-scan on cursor
position
-On the edge of a
pore in the weld -
Depth of the pore in
the spot weld
In the yellow gate: Echo of a pore
Spot weld test
High tension steel plate
Measuring dimensions:
•Size of the nugget
By drawing an
ellipse around the
contour the
dimension is
calculated
Cursor controlled dimension measurement in C-scan.
Spot weld test
High tension steel plate
Time Of Flight
Indentation
Test parameters:
•Indentation measurement
by Time Of Flight (TOF)
Time Of Flight (TOF)
Reference:
A-scan of position
beside the spot
weld.
Arplas weld
Steel plate
Test parameters:
•Shape of the Arplas
weld
A-scan on cursor
position
- besides the weld -
Plate thickness first plate
In the yellow gate: back wall echo of the first plate
Arplas weld
Steel plate
Test parameter:
•Thickness of the
Arplas weld
A-scan on cursor
position
- on the weld -
Thickness weld
In the yellow gate: No weld echo (good welded in that position)
In green gate: Back wall echo of the spot weld
Arplas weld
Steel plate
7,20
Test parameter:
•Detail of the Arplas
weld
•Detecting dimensions
(By moving the cursor)
1,05
A-scan on cursor
position
- on the edge of the
weld -
In the yellow gate: 90% weld echo
(green-red colored pixel, on the edge of the weld)
Software
•Storage of A-scans (ultrasonic signal) for each scanning point
•After event data evaluation possible by gate repositioning
•Ultrasonic settings storable as pre-set for typical applications
•Numerical wall thickness indication
•Direct C-scan presentation
•Two C-scan presentations with independent gate settings
•No picture processing for C-scan presentation
Application: Nut welding
Welded nut (round)
Welded nut (square)
-- The Mini Scanner was placed on the flat plate side --
Application: laser welding
Laser weld round (Alu plate)
Laser weld round (Alu plate)
-- The Mini Scanner was placed on the flat plate side --
Application: Rivet inspection
Rivet in gearbox part
.
-- The Mini Scanner could be placed on both sides of the part --
Application: Porosity check HP casting
A-scan beside a pore
A-scan on a pore
High pressure cast aluminum 2.0 mm thickness
Since the mini scanner is used in the field a lot of new applications are coming up.
Inspection with the Mini Scanner
Applications
• Multiple plate weld inspection
• Plate thickness 0,5 -8 mm with standard transducers.
• Weld between plates and massive parts
Conditions:
• Scan head has to be placed on a flat surface
• Accessibility scanner to the product
• Use of gel allowable
Practical limitations
Even the mini scanner is subject to
the physical limitations caused by the
properties of ultrasonic pulse echo
techniques, such as:
•Insufficient reflection of the
ultrasonic echo’s
Caused by:
•Disturbance by sharp edges around
the weld
•Raw or dirty surface
•Scanner not good in position during
scanning
Latest developments
Smaller model scan unit
Lower weight: -40 %
Reduced scan time: -20%
Concluding
•Handy ultrasonic C-scan device for detailed weld inspection
•Multiple ultrasonic signal evaluation modes
•Storage of all ultrasonic data
•Improved welding process control possible by inspection on location