NDE Approaches for Enhanced Performance and NDE Approaches for Enhanced Performance and Mitigation of Risks in Demanding TechnologiesMitigation of Risks in Demanding Technologies

BaldevBaldev RajRaj

E-mail: baldev.dr@gmail.com

PresidentPresident --Research PSG InstitutionsResearch PSG InstitutionsPresidentPresident --Research PSG InstitutionsResearch PSG InstitutionsPresident Indian National Academy of EngineeringPresident Indian National Academy of Engineering

President, International Institute of WeldingPresident, International Institute of WeldingJC Bose, National Fellow; DSTJC Bose, National Fellow; DST

CoimbatoreCoimbatore

Plenary Address Plenary Address Plenary Address Plenary Address Plenary Address Plenary Address Plenary Address Plenary Address –––––––– 18 WCNDT18 WCNDT18 WCNDT18 WCNDT18 WCNDT18 WCNDT18 WCNDT18 WCNDT--------2012, Durban, South Africa, 162012, Durban, South Africa, 162012, Durban, South Africa, 162012, Durban, South Africa, 162012, Durban, South Africa, 162012, Durban, South Africa, 162012, Durban, South Africa, 162012, Durban, South Africa, 16thththththththth April, 2012April, 2012April, 2012April, 2012April, 2012April, 2012April, 2012April, 2012

Challenges ….. Challenges …..

� Increasing demands on clean and competitive energy, water, agriculture and healthcare. (These demands are to be met with ethics and equity)

� Longetivity – old age problems – newer strains of diseases

� Ageing assets and new high performing assets

� Globalisation of economies – increased competitions – to be met with competence, innovations and ethics

� Increased social and work stresses

� Human resources (engineers) to meet the challenges

Directions of Technology Directions of Technology

� Technologies performing at frontiers of limits of performance

� Very large structures plants to nano devices

� Design, analysis, virtual reality, health diagnosis, Asset Management

� Innovations in all stages of life cycle of technology (evolutionary, paradigm changes, cascade, …innovation ecosystem)

� Newer materials processes and performance (modelling and simulation, advanced characterization, testing and analysis for extreme conditions)

� Advanced sensors, wireless networks, embedded systems, on-line measurements and their analysis.

Management……Management……� Simple and Robust management principles and practices

� Paradigm shifts in management concepts(fast, diverse, organic vs inorganic growth,…)

� Interdisciplinary decisions : A wide spectrum in cultures of countries, religions, competences, bureaucracies, priorities.

� Ethics, Equity

� Engineering Challenge – Fractured linkages leading to weakness in decisions

Accidents ……Accidents ……

Challenger disaster, Jan 1986 Concorde disaster – July 2000

Bhopal gas tragedy Dec. Bhopal gas tragedy Dec. 19841984

Fukushima accidents, Mar. 2011Gulf of Mexico Apr. 2010

Prediction, Management of black swan, fat tail, low probability but high risk accident scenarios Prediction, Management of black swan, fat tail, low probability but high risk accident scenarios

� Improper Design and Materials (Challenger),

� Inadequate safety and regulatory practices (Bhopal )

� Improper PSI, ISI, TQM (Gulf of Mexico)

Analysis……Analysis……

� Inadequate defense in depth and lack of organisatio naldecision making (Fukushima)

Common Thread in all the above ….� Measurements(relevance,adequacy,sensitivity,robustn ess)

� Inadequate analysis and correlation to performance in steady state and accident scenarios

DNA of Plant longetivity with risk mitigations….DNA of Plant longetivity with risk mitigations….

Steady State Steady State PerformancePerformance

Extended life Extended life with robust with robust

performance performance

Knowledge of Knowledge of AssetAsset

OnOn--line and line and Periodic inPeriodic in--situ situ

Monitoring using Monitoring using Measurements Measurements performance performance and enhanced and enhanced

productivityproductivity

Probabilistic + Deterministic Probabilistic + Deterministic Risk AnalysisRisk Analysis

Review+ Review+ FeedbackFeedback

Monitoring using Monitoring using advanced advanced

technologies technologies

Minimum Minimum Excursions Excursions

and Outagesand Outages

Measurements Measurements ++

NDE NDE PlanPlan

ImplementImplement

DemonstrateDemonstrate

MeasureMeasure

Analysis Analysis

ImproveImprovewithwith

FeedFeed--back back

Infrastructure and

Facilities

Multi NDE and Fusion ofimages

and signals

Nurturing relevant Human

Resources

NDE

Synergy of Expertise and facilities

NDE Waves ….

Sensors and Instrumentation

Basic Physics Materials Science

Modelling and Simulation

NDE

Challenges in newer Materials – design,

development and manufacturing

Enhanced Capability….

1010

“ “ The country that learns to build The country that learns to build

breeder reactor would have solved breeder reactor would have solved

its energy problems for ever its energy problems for ever ””

“ The country which first develops “ The country which first develops

a breeder reactor will have a great a breeder reactor will have a great

competitive advantage in Atomic competitive advantage in Atomic

Energy ” Energy ” -- India made an early entry to India made an early entry to

Nuclear EnergyNuclear Energy

A Visionary’s Dream on Nuclear A Visionary’s Dream on Nuclear Sodium Cooled Reactors . . . . Sodium Cooled Reactors . . . .

Enrico Fermi Nuclear Generating StationEnrico Fermi Nuclear Generating Station1901 1901 -- 19541954

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Equity through TechnologyEquity through Technology

Nuclear EnergyNuclear EnergyBreeding ratio: “ . . . it obviously must be great er Breeding ratio: “ . . . it obviously must be great er

than one ”. than one ”.

“ The serious objection to these fast chain piles i s “ The serious objection to these fast chain piles i s

the removal of heat ”. the removal of heat ”.

“ The coolant for this type of pile would be a “ The coolant for this type of pile would be a

bismuthbismuth--lead alloy and would flow downward lead alloy and would flow downward

through the pile between the static and rotating through the pile between the static and rotating

rods. The possibility of using liquid sodium in rods. The possibility of using liquid sodium in

place of bismuthplace of bismuth--lead should also be looked into ” . lead should also be looked into ”.

[ India pursues a vibrant Fast Reactor Program][ India pursues a vibrant Fast Reactor Program]

Enrico Fermi, Meeting in April 26, 1944 Enrico Fermi, Meeting in April 26, 1944 With Wigner, Szilard and Others on With Wigner, Szilard and Others on ::

“ How the Chain Reaction would be used for “ How the Chain Reaction would be used for the production of power ”the production of power ”

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FBR PROGRAMME IN INDIAFBR PROGRAMME IN INDIA

10 0907 08

06

04 05

03

11

1372

5

Ø11950

Future FBRFuture FBR

•• 1000 MWe1000 MWe

Credible confidence in

fuel cycle

Human resources

Human resources

25 years ofsuccessfuloperation

StateState--ofof--art art

conceptsconcepts

Innovative concepts

03

02 0112

FBTRFBTR•• 40 40 MWtMWt (13.5 (13.5 MWeMWe) )

•• Loop type reactor Loop type reactor

•• PuPuC C –– UCUC

•• Design: CEA, FranceDesign: CEA, France

Since 1985Since 1985……

PFBRPFBR•• 1250 MWt (500 MWe)1250 MWt (500 MWe)

•• Pool TypePool Type

•• UOUO22--PuOPuO22

•• Indigenous design and Indigenous design and constructionconstruction

•• To commission in 2012To commission in 2012

CFBRCFBR

•• 500 MWe500 MWe

•• Pool TypePool Type

•• UOUO22--PuOPuO22

•• Six units (3 twin units) Six units (3 twin units)

•• To commission in 2023To commission in 2023

•• Pool TypePool Type

•• Metallic fuel Metallic fuel

•• Serial Serial constructionconstruction

•• Beyond 2025Beyond 2025

Technological Challenges in FBRTechnological Challenges in FBRCompact Reactor Core With High Fissile ContentCompact Reactor Core With High Fissile Content

Use of Liquid Na as Coolant at high temperatures ( ~ 823 K) Use of Liquid Na as Coolant at high temperatures ( ~ 823 K)

Design and fabrication of Materials that can withstand intense neutron dose, temperature, and Design and fabrication of Materials that can withstand intense neutron dose, temperature, and loadings including Seismicloadings including Seismic

Reprocessing of highly active spent fuelReprocessing of highly active spent fuel

High Level waste management is very important for the success of Nuclear OptionHigh Level waste management is very important for the success of Nuclear Option

Achieving High Performance with

risk mitigation

Analysis based on Analysis based on ModellingModelling and and

SimulationSimulation

Our approaches to challenges …Our approaches to challenges …

Validation through Validation through accurate and accurate and

sensitive sensitive measurementsmeasurements

Technology Technology Development (1:1 or Development (1:1 or

scaled down scaled down models)models)

Knowledge Knowledge Management, Management,

feedback Design, feedback Design, Visionary ISIVisionary ISI

ISI of FBR ComponentsISI of FBR Components� In-Core Components

� Fuel subassemblies

� IHX, Roof slab

� Discharge pipe etc.

Issues - Access constraints, background radiation,

temp., opaque sodium thus limited possibility

for inspection

Approach - Stringent quality assurance (QA)Approach - Stringent quality assurance (QA)

Visual examination & under Sodium Ultrasonic’s

viewing employed

� Out-of-Core Components

� Main vessel / Safety vessel

� Steam generators / Sodium circuit pipes

� Concrete containment etc.

Issues: Access restrictions, temperature, time of inspection

Approach : Stringent QA +Advance NDE methods + Robotic devic es

developed for ISI

Visual Examination Visual Examination SystemSystem

Test Trolley Test Trolley developed developed

for for validation validation

Ultrasonic Test SystemUltrasonic Test System

DISHA ModelDISHA Model

DISHA DISHA AssemblyAssembly

�� Temperature during ISI Temperature during ISI -- 150 150

mm mm

�� Temperature during ISI Temperature during ISI -- 150 150

°°°°°°°°CC

�� MVMV--SV InterSV Inter--space space -- 300 300 ±± 50 50

mm mm

High Temperature Test High Temperature Test FacilityFacility

validation validation of of

kinematic kinematic parametersparameters

ISI marking on SV for ISI marking on SV for navigation of ISI devicenavigation of ISI device

Image of an artificial Image of an artificial crack through the Visual crack through the Visual

examination systemexamination system

Existing ISI Device for SG tubes Improved ISI device for SG tubes

Flexible Flexible

Robotic Robotic

armarm

Linear ActuatorsLinear Actuators

PulleysPulleys

Robot’s baseRobot’s base

ExciterExciter

ReceiverReceiver

Depleted UDepleted U

ringsrings

WINCHWINCH

Improved Device for ISI of SG Improved Device for ISI of SG tubes tubes

(SPATIAL HYPER REDUNDANT (SPATIAL HYPER REDUNDANT ROBOT)ROBOT)

Computer aided Computer aided simulation simulation

One set of One set of DiscDisc

Spider Robot On MockSpider Robot On Mock--up up

SG Tube SheetSG Tube Sheet

ISI Device being deployed in SG for ISI Device being deployed in SG for testingtesting

Remote Field Eddy Current Technique

DiscretisedDiscretised meshmeshFEM predicted poynting FEM predicted poynting vector plots of energyvector plots of energy

Detector Detector locationlocation

Optimal Optimal 1.8

2x 10

-5

700 Hz900 Hz1100 Hz

5x 10-6

ExciterExciter

0.9

1ModelExperimental 40% WL40% WL

RFEC technique PrincipleRFEC technique PrincipleRFEC technique involves detection of back entered lowRFEC technique involves detection of back entered low--frequency frequency

magnetic fields (energy) in tubes using a receiver coilmagnetic fields (energy) in tubes using a receiver coil

Optimal Optimal excitation excitation

frequency & frequency & detector location detector location

where RFEC where RFEC intensity is intensity is maximum maximum

determined using determined using 3D finite element 3D finite element

model and model and results validatedresults validated

1.9 2 2.1 2.2 2.3 2.4 2.5 2.6 2.7 2.80

0.2

0.4

0.6

0.8

1

1.2

1.4

1.6

1.8

Receiver coil location, ID (12.6 mm) times

Indu

ced

volta

ge in

the

Rec

eive

r co

il, V

olts

1100 Hz1300 Hz1500 Hz1100 Hz Experimental

800 900 1000 1100 1200 1300 1400

1

2

3

4

Frequency, Hz

RF

EC

Inte

nsity

, Vol

ts

RFEC zone for RFEC zone for detectordetector

Instrumentation difficultyInstrumentation difficulty

1100 Hz (optimum)1100 Hz (optimum)

50 100 150 200 250 300 350 400 450 500 5500

0.1

0.2

0.3

0.4

0.5

0.6

0.7

0.8

0.9

Scan position, mmR

FE

C A

mpl

itude

, V

olts

20% WL20% WL

10% WL10% WL

30% WL30% WL

40% WL40% WL

Model validation Model validation

S. Thirunavukkarasu, B.P.C. Rao, S. Mahadevan, T. Jayakumar, Baldev Raj, Z. Zeng, L. Udpa and S. S. Thirunavukkarasu, B.P.C. Rao, S. Mahadevan, T. Jayakumar, Baldev Raj, Z. Zeng, L. Udpa and S. Udpa, Journal of Research in NDE (USA), Vol. 20, 2009, pp 1Udpa, Journal of Research in NDE (USA), Vol. 20, 2009, pp 1--88

RTDS sensor developed for temperaturemeasurement on sodium loops (up to 700°C withspatial resolution of 1 m and temp. resolution of5°, limited by laser pulse width)

Fiber Bragg gratings designed and developed forstrain measurement on a test loop

Development of Optical Fiber based Raman Distributed Temperature (RTDS) Sensor

Acrylic ~ 100ºCPolyamide ~ 300ºC

Pulse Laser

Thermally influenced

� Leak detection is possible. For technology demonstration,controlled leaks were simulated using hot water as coolant.

�Spatial, statistical and temp. dependent errors analyzed t oimprove the leak detection capability in coolant loops ofreactors. Test loop for testing

molecular vibrationscause Raman backscattered light whoseintensity and arrivaltime are used fortemperature andlocation monitoring Single fiber grid was used to increase

the spatial resolution up to 10 times

Laser scattering for Sensing Surface DamageLaser scattering for Sensing Surface Damage

AFTER IGC ATTACKAFTER IGC ATTACKAS POLISHEDAS POLISHED

0 20 40 60 800.0

0.2

0.4

0.6

0.8

1.0

E tching tim e, sec

Specular reflection, Arb. units

0 20 40 60 80

0.8

0.9

0.4

0.5

0.6

0.7

Etching time, sec

FWHM (X 10mm)

1.0

Evaluation of Intergranular Corrosion in SSEvaluation of Intergranular Corrosion in SS

Most of the Damage Mechanisms initiate from the sur facesMost of the Damage Mechanisms initiate from the sur faces

23Pitting CorrosionPitting Corrosion Effect of etching time on IGC in SS Effect of etching time on IGC in SS

20 s20 s 80 s80 s

20 s20 s 80 s80 s

Intergranular corrosion detection in Waste tanks by ECIntergranular corrosion detection in Waste tanks by EC--GMR sensorGMR sensor

ExciterExciter –– Eddy current coil, Eddy current coil,

ReceiverReceiver: GMR sensor: GMR sensor

Giant magneto-resistive (GMR) effect is large change in res istance of nano layers due to appliedmagnetic field as a result of spin dependent scattering of el ectrons. In order to pick-up feeblemagnetic fields produced by eddy currents (EC) at sub-surfa ce corroded regions, GMRsensor has been integrated with eddy current coil. GMR sensi tivity: 10 nano Tesla

EC coilEC coil

GMR chipGMR chip

Corroded

Un-C

orroded

4mm

7mm

4 5 6 7 8 90 .00

0 .05

0 .10

0 .15

0 .20

0 .25

0 .30

0 .35

0 .40

0 .45

0 .50

Sen

sor

Out

put D

iffer

ence

, mv

D ep th b e lo w S u rfa ce , m m

E C -G M R respo nse 0.5 h r 1 h r 2 h rs

E C respo nse 0.5 h r 1 h r 2 h rs

EC-GMR sensor is capable to detect corrosion 9 mm below the surface

SuccessfulSuccessful applicationapplication forfor detectiondetection ofof internalinternal corrosioncorrosion inin 1212 mmmm thickthick 304304 LLwastewaste vaultvault tanktank byby scanningscanning fromfrom outerouter surfacesurface –– ISIISI tooltool withwith roboticsrobotics ..

GMRGMR 9mm

12mm thick AISI type 304L plate (Oxalic acid attack) EC-GMR Images

Corrosion an Inherent Problem-Solution through Inno vative Approach with Advanced NDE

Phase Image - Lock in Thermography

Quantitative Estimation

of

Corrosion in Structural

Elements

Two Novel and Complementary

Techniques

Robust

Life Phase Image - Lock in Thermography

Compton Back Scattering

Asset History

Environmental Details

Modelling

Risk Management

Life

Prediction

for

Structural

Longevity

Potential techniques for one sided inspection Potential techniques for one sided inspection suitable for large structures. Can give quantitati ve suitable for large structures. Can give quantitati ve

estimation of corrosion and also detect rebar estimation of corrosion and also detect rebar corrosion corrosion

Monte Carlo Numerical PredictionMonte Carlo Numerical Prediction

0.2950

0.2975

0.3000

0.3025

0.3050

0.3075

0.3100

0.3125

0.3150

0.3175

0.3200

0.3225For the Inconel 625 wrought cracker tubes at HWP, Thal and HWP, Tuticorin in various thermal exposure conditions

Poi

sson

's r

atio

Virgin (Thal) RSA (Thal) V+747 h (Tuti) RSA+23000 h (Thal) V+57194 h (Tuti) Failed in 1982 (Tuti) MC (~20000h) (Tuti) 120000 h (1-35, Thal)

�Ultrasonic measurements can be used to monitor the degradation in mechanical properties

−

−=

12

2

2

2

2

2

L

S

L

S

TOF

TOF

TOF

TOF

ν

Accuracy ~ ±±±± 0.0006

Service exposed (SE) : NH3cracker tube at ~873 K

1 hr and 600 hrs

120 140 160 180 200 220 240 260 280 300 320 340 360 3800.2925

0.2950

Hardness, VHN

120000 h (1-35, Thal) 120000 h (36-70, Thal)

Variation in Poisson’s ratio with hardness for cracker tubes in different service exposed conditions at heavy water plants at Thal and Tuticorin. (V-Virgin, MC-Mini Cracker, RSA-Re-solution annealed)

�Life span of these tubes for resolution annealing should not be based on merely the service duration, but on some practically measurable parameter, such as Poisson’s ratio and hardness

�Assessment of rejuvenation heat treatment of the tubes using ultrasonic measurements

Reused after rejuvenation by resolution annealing (RSA)

Magnetic Flux Leakage (MFL) ImagingMagnetic Flux Leakage (MFL) Imaging

YokeYoke

Carbon steel plateCarbon steel plate

ScannerScanner

GMR SensorGMR Sensor

MFLMFL imageimage ofof aa notchnotch locatedlocated atat66..22 mmmm belowbelow surfacesurface inin aa 1212 mmmm

MFL images of defects are obtained by MFL images of defects are obtained by scanning Giant Magnetoscanning Giant Magneto --Resistive (GMR) Resistive (GMR) 66..22 mmmm belowbelow surfacesurface inin aa 1212 mmmm

thickthick carboncarbon steelsteel plateplate

AA flexibleflexible arrayarray ofof eighteight GMRGMR sensorssensors developeddevelopedforfor automaticautomatic fastfast detectiondetection ofof flawsflaws andand lossloss ofofmetallicmetallic areaarea (LMA)(LMA) inin multimulti--strandstrand steelsteel wirewire ropesropes

scanning Giant Magnetoscanning Giant Magneto --Resistive (GMR) Resistive (GMR) sensor in a raster manner over the object.sensor in a raster manner over the object.

Array of 8 GMR sensorsArray of 8 GMR sensors

Scan Scan directiondirection

ResponseResponse ofof GMRGMR arrayarraysensorsensor toto sawsaw cutscuts inin 6464 mmmmdiameterdiameter wirewire roperope

5 saw cuts 5 saw cuts

Wire rope of HWP, ManuguruWire rope of HWP, Manuguru

Structured Approach to Asset ManagementStructured Approach to Asset Management

Asset Management

Design Objectives

Materials and Asset ManagementMaterials and Pre-service Data(Fabrication,

Machining,Welding

Qualification, etc)

Repairs and In-service Data

International Experiences

Asset and Knowledge Base essential for plants Asset and Knowledge Base essential for plants intended to serve for more than 40 years. The intended to serve for more than 40 years. The knowledge base is designed to serve as an expert knowledge base is designed to serve as an expert system for bigger plants. system for bigger plants.

Asset and Knowledge Management System (AsKMe)

Archives more than 40,000 documents,

records and drawings pertaining to

Demonstration Fuel Reprocessing Plant.

Unique features that distinguish it from

conventional database

Radiographic archive with user defined

(based on experience) software for

image analysis and measurements

Provision for Ultrasonic signals andProvision for Ultrasonic signals and

images with analysis

Knowledge capsule _ Interviews with

senior/retired project colleagues on field

problems and their innovative solutions.

Quality Circle problems and solutions

First of its kind attempt in DAE and

internationally. Appreciated by

Regulators.

Implementation of Six Sigma

Study envisaged the application of six sigma in the fabrication of complex and high density piping. 35,000 weld joints.

12,000 studied.

� Main types of defects that arise could be identified.

� Root causes of the defect could be ascertained to prevent in future pipings.pipings.

�R & D initiated – for example oxidation occurs because of lack of purging gas.

�Feasibility studies on using Flux cored / covered TIG welding filler wires to completely eliminate the purging.

�Trial implementation made in complex piping.

�100 % oxidation free joints achieved.

VALIDATEDDESIGN

FOCUSSEDINTER-

DISCIPLINARYRESEARCH PROVEN

MANUFACTURING TECHNOLOGIES

ROBUST

SUCCESSFUL LIFE CYCLE SUCCESSFUL LIFE CYCLE PERFORMANCE REQUIRE…PERFORMANCE REQUIRE…

INNOVATIVEINNOVATIVE APPROACHES,APPROACHES, SEAMLESSSEAMLESSINTEGRATIONINTEGRATION OFOF DISCIPLINESDISCIPLINES ANDANDENABLINGENABLING TECHNOLOGIESTECHNOLOGIES INTEGRATEDASSET AND KNOWLEDGE MANAGEMENT

RELIABLESENSORS,SYSTEMS

SAFE OPERATION

PROCEDURES

SYSTEMATIC, PLANNED ISI,

LIFE ASSESSMENT

ROBUST INSPECTION

and TQM

ASSET AND KNOWLEDGE MANAGEMENT

Approach for Implementing Innovations

• Critically review the internationally evolving designs and failure experiences

• Detail out the prospective options for future SFRs• Involve Industries to design and manufacture innovative

concepts • Academic institutes for design optimisation by analysis

• Recognising priorities, breakthrough areas by experts, young students and research scholars at the core of innovation

• Innovations eco-system with intertwining of young, senior, academic, research and industry

• Quality and motivated human resources with enabling networks and management ethics is a key to the safety of SFR

• Academic institutes for design optimisation by analysis• Testing in air at Industries and testing in sodium at IGCAR

Challenges : Miniature IR sensors, thermal noise, feature detection and identification Challenges : Miniature IR sensors, thermal noise, feature detection and identification –– robust robust fuzzy logic based systemsfuzzy logic based systems

RE

SID

UA

L S

TR

ES

S, M

Pa

-200

-300

-100

100

0

RE

SID

UA

L S

TR

ES

S, M

Pa

-300

-100

-200

0

XRD based Residual Stress Measurements for Life Assessment of Undercarriages of Fighter Aircrafts

NUMBER OF LANDINGS

-6000

RE

SID

UA

L S

TR

ES

S, M

Pa

-400

-500

-300

800400

1200

RE

SID

UA

L S

TR

ES

S, M

Pa

-6000

-400

-500

300DEPTH IN MICRONS

100 200

In collaboration with IAF & HAL, Nasik

The variation in residual stress in the depth direction

Number of Landings = 1050

Surface residual stress

The variation in surface residual stress in landing gears experienced different number of landings

Stresses,

microstructures,

micro and macro

defects through

X-ray diffraction for life

assessment of landing gears of

MIG-21

Micropores,

impact

damage, fibre

breakage in

composites

through

Remnant

core in

turbine -

K

7-FRONT

8-REAR

5-FRONT

6-REAR

3-FRONT

4-REAR

9

10

VIEW -K

2

1

REGIONS OF RESIDUAL

MAIN LANDING GEAR STRUT

STRESS MEASUREMENTS

MIG-21/23

Radiation based NDE

at IGCAR

through

micro focal

NDE

Inclusions, Glue variations,

Quality Assurance of assemblies

–

Conventional X-ray

turbine -

through

Neutron

Radiography-

KAMINI

Mi-8/17LCA

The simulation paradigmThe simulation paradigm

From: From: KuivanenKuivanen, ‘e, ‘e--Engineering (Digital Manufacturing)’Engineering (Digital Manufacturing)’, , VTT (Technical Research Centre of Finland), VTT (Technical Research Centre of Finland), 2010.2010.

www.monash.eduwww.monash.edu

Courtesy,

CSIRO, Australia

Courtesy,

CSIRO, Australia

Factors Affecting Measurements in NDEFactors Affecting Measurements in NDE

Material Material PropertiesProperties

Measurements Measurements in NDEin NDE

Sensor Sensor characteristicscharacteristics

Operator Operator qualification qualification and trainingand training

AutomationAutomation

Fixed Factors Fixed Factors Variable FactorsVariable Factors

Automation Automation

+ +

Defect Detection based on large defect database Defect Detection based on large defect database

+ +

Heuristic Knowledge of Experienced OperatorsHeuristic Knowledge of Experienced Operators

Inherent Noise Inherent Noise from sensor from sensor

and electronicsand electronics

Image and Image and Signal Signal

ProcessingProcessing

Six SigmaSix SigmaAsset & Knowledge Asset & Knowledge ManagementManagement

Indicates significanceIndicates significance

Analysis

Code

Model

Interactions

Materials

Microstructure

Production

Technology development

Modelling and Simulation

Sensors and NDT

Quality Assurance

Performance evaluation

Operator

Integration

Simulation

Software

ISI

NDE and Sensors

Review

Analysis

POD

Criteria

PERFORMANCE OF HIGH TECHNOLOGY PERFORMANCE OF HIGH TECHNOLOGY

COMPONENTS AND SYSTEMS COMPONENTS AND SYSTEMS -- MATURITY MAPPING MATURITY MAPPING

Microstructure

Composition

AssuranceHardware

Criteria

DesignManufacturing Technologies

Operation and maintenance

Health Monitoring

�� Excellence in Individual DomainsExcellence in Individual Domains

�� Fractured LinkagesFractured Linkages

�� Barriers of Disciplines and ManagementBarriers of Disciplines and Management

�� Lack of Integrated and holistic approachesLack of Integrated and holistic approaches

Challenging engineering and technological problems need…

Robust Measurements

Sensors

Electronics

Statistics

Sciences

Systems

Robust Analysis Clear Convincing even to concerned +

Galileo

Robust Analysis even to concerned non-specialists

+

Challenger Failure – Successful and Well Appreciated Solution based upon

Holistic Analysis with robust measurements and clear convincing

Richard Feynman

My Perspective of Missing Links …..� Measurements crucial for successful performance

Robust &

Quality &

Safety in Life

Health

High

Performance

System

How well have we understood and translated …How well have we understood and translated …

Relevant

Measurements

EnvironmentCultural Heritage

Health System

AVALANCHE

I

Acoustic Simulation of

PE-16 (µm size

precipitates) – Ph D

Thesis IzfP Germany

Kaiga Ring beam using

acoustic impact echo testing

Small innovative ideas triggering research and application spanning disciplines and organisations

Acoustic amplification based tests

for dislocation studies (µm-nm)

INNOVATIONS

Acoustic study of Humpy

musical pillars

Ca Oxalate kidney stone

acoustic microscopy

(10 nm thick layers)

AE energy / load vs.

normalized time

curve

Damage Micro-mechanisms in

Near Alpha Titanium Alloy

Defence Lab (DMRL)

Understanding Movement of

Dislocations with Acoustics

Ethical & Sustainable modelEthical & Sustainable model