Robotic Laser Beam Reduced Pressure Welding: Narrow Gap Laser Cleaning Capability Development

In this section

Back to Core Research Programme AMorph – 4D Printing for Field Morphing Structures Automation of Composite and Hybrid Joining Process Coaxial Wire Additive Manufacturing Processes and In-Line Monitoring Tools Development of Coded Excitation Technique for Non-Metallic Pipes Inspection Development of Digital Twin technology as a demonstrator for real-time integrity assessment of crack growth in tensile specimens Development of Friction Stir Welding (FSW) for Hydrogen Fuel Storage Tanks Development of Leak-Before-Break Hydrogen Storage Composite Pressure Vessels With Polymeric Liner Establishing Assessment Methods for Determining Safe Service Limits of High-Temperature Materials in Extreme Environments Fracture toughness in aggressive environments: effect of crack monitoring techniques on test results In-process detection and non-destructive testing of electron beam weld imperfections Internal Bore Coatings for Applications in Corrosion and Hydrogen Environment Joining of Additively Manufactured Materials Long term behaviour of polymeric liner materials/coatings in hydrogen service Techniques for High Temperature Ultrasonic Inspection of Arc Welding Ultimate Leverage Fund

Project Code: 36207

Start date and planned duration: January 2025, 24 months

Objective

Development of ultrasonic techniques to inspect welds with intact caps including (a) through weld cap inspection using Adaptive Total Focusing Method (ATFM) and conformable probes (b) skew beam inspection from adjacent base metal using linear or 2D arrays
Develop a range of test pieces containing representative flaws to support evaluation of developed techniques
Experimental testing of developed techniques to assess the feasibility to inspect welds with intact caps using ultrasonic testing

Project Outline

This project seeks to develop ultrasonic testing techniques to enable inspection of welds with a probe located directly on an intact weld cap. The work will build upon existing capability within TWI to generate suitable focal laws to allow focused images of the weld body using the ATFM algorithm.

Flaws of primary interest are transverse planar indications within the weld body or heat affected zone e.g. transverse hydrogen cracking.

Within the scope several low carbon steel test pieces shall be manufactured with a range of weld cap configurations and representative flaws to demonstrate capability and support a portfolio of evidence for this relatively new inspection capability.

Industry Sectors

- Oil and Gas

- Power Generation

- Civil Nuclear

- Defence

Benefits to Industry

Ultrasonic testing through an intact weld cap may eliminate the need to remove the cap, offering cost and time reductions associated with machining processes.
Supports the industry demand for ultrasonic testing in lieu of radiography. Radiography does not require weld cap removal. If ultrasonic testing can also be performed with the cap intact this increases the range of applications where it may replace radiography leading to:
1. Improved safety due to removal of ionising radiation
2. Time and cost savings associated with the removal of radiographic exclusion zones