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Use of automatic image processing for monitoring of welding processes and weld inspection
A new concept of magnetic particle inspection (MPI) was developed and will be presented. It includes, modeling of MPI based on Maxwell's equations and using finite element calculations. The design of multi- circuit MPI systems after a modeling process becomes state of the art. Installation, measurement and control of MPI system parameters is undertaken by sengors and microprocessor electronics. There is also automatic handling of illumination and evaluation using robotics, cameras, image processing systems and fully automated accept/reject- decision-computers,
40890 Link, R.; Busse, H.P.; Stapf, C.; Streckenbach, G.; Wiacker, H.; Zindler, W,; Disselhorst, K.; Burghoff, H.; Schulz, R.; Stolzenberg, E. A system for automated surface crack detection in magnetic particle inspection Proceedings of the 12th World Conference on Non-Destructive Testing, Amsterdam (Netherlands) 23-28 Apr. 1989, Vol. 1, pp. 667-669. Edited by J. Boogaard and G.M. van Dijk, Elsevier, 1989 The magnetic particle inspection is a widely used nondestructive testing method for the detection of surface cracks in the automotive industry. This method is applied by the manufacturer as well as after machining and before assembling in the automobile industry. At the second 100% inspection, with rates of 500,000 to 1,000,000 pieces per year, only very few defects are found by the operator (less than 10 defects/year). Inspection of such a large number of parts with such a low rejection rate places great demands on the human operator. It is very difficult for him to maintain his attentiveness and concentration under such conditions. These problems in connection with economical aspects almost demand an automated evaluation by a computerized image processing system. 40859
Teichert, H.D.; Rose, P.; Heidt, H.
Neutron radiography analysis by means of image processing Proceedings of the 12th World Conference on Non-Destructive Testing, Amsterdam (Netherlands) 23-28 Apr. 1989, Vol. 1, pp. 860-865. Edited by J. Boogaard and G.M. van Dijk, Elsevier, 1989 Neutron radiography testing is, for certain applications, a useful alternative to the standard X-ray testing methods. Applied image processing can increase this advantage. In this paper some results of image processing analysis on neutron radiographs of industrial components are presented. Examples of image enhancement and defect detection are shown. Typical problems like overlay structure suppression and contrast agent detection are discussed. 40855
Arun Junai, A.; Hofstede, A.; Koster, H.; van Wolferen, H.
Automatic radiographic film evaluation by Kontron SEM-IPS Proceedings of the 12th World Conference on Non-Destructive Testing, Amsterdam (Netherlands) 23-28 Apr. 1989, Vol. 1, pp. 120-121. Edited by J. Boogaard and G.M. van Dijk, Elsevier, 1989 Quality of arc welding electrodes are assessed by first preparing test welds and then subjecting the test welds to a radiographic soundness test as recommended by ASME Section IIC. Kontron scanning electron microscope image processing system (SEM-IPS) is normally used for quantitative analyses of microstructures of different materials. Some of the built-in facilities of the Kontron were made use of along with a specially developed software for the automatic evaluation of the above mentioned radiographic films. The image from the test radiographic films were first captured by a video system for which a bright-field condenser illuminator was used. Image processing operations were carried out using the functions of the Kontron software with which the weld defects could be isolated from the image. A welding electrode quality evaluating software was developed and incorporated in the system. This classifies the above isolated defects on the basis of size/distribution and compares the porosity and inclusion standards for carbon steel arc welding electrodes as per ASME SEC IIC Part SFA-5.I. 40842
Stegemann, D.; Fette, F.; Reimche, W.
Use of real time microfocus radioscopy for investigation of light metal casting processes Proceedings of the 12th World Conference on Non-Destructive Testing, Amsterdam (Netherlands) 23-28 Apr. 1989, Vol. 1, pp. 57-61. Edited by J. Boogaard and G.M. van Dijk, Elsevier, 1989 In this survey an IN-LINE-PRODUCTION-CONTROL-SYSTEM for light metal casting is described using the salient features of dynamic radioscopy with microfoeus technology and digital image processing. In automatic production lines this newly developed, real time radioscopic method allows the early detection of defects and while recognizing a great number of misrun castings during the casting process. It is able to influence and optimize the casting parameters preventing the manufacturer from producing scrap or castings of lower quality. The presented system opens a new door for quality control and material investigation, 40838
Eckelt, B.; Meyendorf, N.; Morgner, W.; Richter, U.
Use of automatic image processing for monitoring of welding processes and weld inspection Proceedings of the 12th World Conference on Non-Destructive Testing, Amsterdam (Netherlands) 23-28 Apr. 1989, Vol. 1, pp. 37-41. Edited by J. Boogaard and G.M. van Dijk, Elsevier, 1989 Advantageous incorporation of image processing into quality assurance in automatic welding is exemplified by thermography as well as flaw detection by radiography. The problem area of monitoring the temperature regime has been solved, permitting quality assurance of specified mechanical and process properties. Weld flaws are automatically detected and satisfactorily evaluated by
NDT International June 1990
means of radiographs. Work is in hand to improve the hardware and flaw classification as a function of the load conditions expected. 40722
Ahmed, T.; Feng, Z.J.; Kuo, P.K.; Hartikainen, J.; Jaarinen,
J. Characterization of plasma sprayed coatings using thermal wave infrared video imaging Journal of Nondestructive Evaluation, Vol. 6, No. 4, pp. 169-175 (1987) A pulsed (time-domain) thermal wave infrared video imaging technique, using an IR camera, a video image processor, and a flash lamp, is described. This system is applied to the imaging of interfacial defects in plasma sprayed coatings on metallic substrates. Results are compared with the conventional point-scanned cw infrared thermal wave imaging technique. 40511
Hitachi Construction Machinery Co., Ltd.
Supersonic flaw detecting system U.S. Patent No. 4,768,155 (30 Aug. 1988) A flaw detection system is described which uses supersonic waves. The object to be inspected is scanned relative to the supersonic emitter probe in two orthogonal directions. Receiver probes convert output to electrical signals which are used as image data for oscilloscope and television display screens. Image processing techniques are employed to manipulate the image memory created from output data. The operator can specify any position on the television monitor by means of the computer control system.
Anathanarayanan, T.S.; Rosemeier, R.G.; Mayo, W.E.; Sacks, S. 40468
Novel non-destructive X-ray technique for near-real time defect mapping Nondestructive Characterisation of Materials 2, Montreal (Canada), 21- 23 Jul, 1986. pp. 657-666. Edited by J.F. Bussiere, J.P. Monchalin, C.O. Ruud, R.E. Green Jr. Plenum Press, 1987 A novel x-ray technique is presented which offers the capability for near-real time defect mapping in a variety of electronic materials. The method relies on a recently developed computer controlled x-ray rocking curve analyzer which utilizes localized x-ray line broadening as a means of quantifying the local dislocation density. By the use of electronic x-ray detectors and image processing techniques, a high quality image of the defect distribution can be produced in a fraction of the time required for conventional x-ray topographs. Moreover, the system requires minimum operator intervention due to its microprocessor control, thus making it ideal as a powerful nondestructive tool for both QC and research applications. The operating principle of the system will be presented along with application to the study of defect distributions in a variety of substrate materials and epitaxial thin films. 40404
Stewart, D. G.
Automatic penetrant evaluation Non-Destructive Testing, Proceedings of the 4th E u r o p e a n Conference, London (United Kingdom), 13-17 Sep. 1987. Vol. 4, pp. 2801-2807. Edited by J.M. Farley and R.W. Nichols. Pergamon Press, 1988 There have been various attempts in the last decade to automate the visualisation and evaluation of fluorescent indications. The USAF, US Army and US Navy, in conjunction with the General Electric Company, started a major automatic inspection development programme called IBIS or Integrated Blade Inspection System. It included the automatic penetrant processing and inspection as a constituent part. The input of expertise in the areas of image processing and pattern recognition is noted. Including a manual 'bleed-back' stage. The enhanced repeatability of the automatic inspection system offers significant improvements in indication validation over human inspection. The need to apply non-linear algorithms in the evaluation of indications is also stressed. 40393
Zheng, Yi.
Image analysis, modeling, enhancement, restoration, feature extraction and their applications in nondestructive evaluation and radio astronomy Dissertation Abstracts International, Vol. 49, No. 2, pp. 507 (Aug. 1988) This dissertation is complied from nine papers and addresses itself to the development and application of signal and image processing to nondestructive evaluation (NDE) generally and to radio astronomy specifically. Topics covered include time series analysis and modeling of Very Large Array (VLA) phase data, image analysis, and feature extraction for industrial NDE radiographic images as well as image enhancement by Kalman filtering and considering signal dependent coloured noise. Robotic image manipulation, controlled by expert systems, is covered. Kalman filtered VLA phase data is studied using a supercomputer x ray and infrared images may be deblurred with the deconvolution method suggested. The last two papers cover local feature enhancement of synthetic radio images by adaptive Kalman filtering and a new technique for correcting phase data from a synthetic-aperture antenna array. 40329
Daum, W.; Heidt, H.; Rose, P.; Builtjes, J.H.
Real time evaluation of weld radiographs by digital image processing Proceedings of the 4th European Conference on Non-Destructive Testing, London (United Kingdom) 13-17 Sep. 1987. Vol. 3, pp. 1568-1574. Pergamon Press, 3173 pp. (1988).
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40890 Link, R.; Busse, H.P.; Stapf, C.; Streckenbach, G.; Wiacker, H.; Zindler, W,; Disselhorst, K.; Burghoff, H.; Schulz, R.; Stolzenberg, E. A system for automated surface crack detection in magnetic particle inspection Proceedings of the 12th World Conference on Non-Destructive Testing, Amsterdam (Netherlands) 23-28 Apr. 1989, Vol. 1, pp. 667-669. Edited by J. Boogaard and G.M. van Dijk, Elsevier, 1989 The magnetic particle inspection is a widely used nondestructive testing method for the detection of surface cracks in the automotive industry. This method is applied by the manufacturer as well as after machining and before assembling in the automobile industry. At the second 100% inspection, with rates of 500,000 to 1,000,000 pieces per year, only very few defects are found by the operator (less than 10 defects/year). Inspection of such a large number of parts with such a low rejection rate places great demands on the human operator. It is very difficult for him to maintain his attentiveness and concentration under such conditions. These problems in connection with economical aspects almost demand an automated evaluation by a computerized image processing system. 40859
Teichert, H.D.; Rose, P.; Heidt, H.
Neutron radiography analysis by means of image processing Proceedings of the 12th World Conference on Non-Destructive Testing, Amsterdam (Netherlands) 23-28 Apr. 1989, Vol. 1, pp. 860-865. Edited by J. Boogaard and G.M. van Dijk, Elsevier, 1989 Neutron radiography testing is, for certain applications, a useful alternative to the standard X-ray testing methods. Applied image processing can increase this advantage. In this paper some results of image processing analysis on neutron radiographs of industrial components are presented. Examples of image enhancement and defect detection are shown. Typical problems like overlay structure suppression and contrast agent detection are discussed. 40855
Arun Junai, A.; Hofstede, A.; Koster, H.; van Wolferen, H.
Automatic radiographic film evaluation by Kontron SEM-IPS Proceedings of the 12th World Conference on Non-Destructive Testing, Amsterdam (Netherlands) 23-28 Apr. 1989, Vol. 1, pp. 120-121. Edited by J. Boogaard and G.M. van Dijk, Elsevier, 1989 Quality of arc welding electrodes are assessed by first preparing test welds and then subjecting the test welds to a radiographic soundness test as recommended by ASME Section IIC. Kontron scanning electron microscope image processing system (SEM-IPS) is normally used for quantitative analyses of microstructures of different materials. Some of the built-in facilities of the Kontron were made use of along with a specially developed software for the automatic evaluation of the above mentioned radiographic films. The image from the test radiographic films were first captured by a video system for which a bright-field condenser illuminator was used. Image processing operations were carried out using the functions of the Kontron software with which the weld defects could be isolated from the image. A welding electrode quality evaluating software was developed and incorporated in the system. This classifies the above isolated defects on the basis of size/distribution and compares the porosity and inclusion standards for carbon steel arc welding electrodes as per ASME SEC IIC Part SFA-5.I. 40842
Stegemann, D.; Fette, F.; Reimche, W.
Use of real time microfocus radioscopy for investigation of light metal casting processes Proceedings of the 12th World Conference on Non-Destructive Testing, Amsterdam (Netherlands) 23-28 Apr. 1989, Vol. 1, pp. 57-61. Edited by J. Boogaard and G.M. van Dijk, Elsevier, 1989 In this survey an IN-LINE-PRODUCTION-CONTROL-SYSTEM for light metal casting is described using the salient features of dynamic radioscopy with microfoeus technology and digital image processing. In automatic production lines this newly developed, real time radioscopic method allows the early detection of defects and while recognizing a great number of misrun castings during the casting process. It is able to influence and optimize the casting parameters preventing the manufacturer from producing scrap or castings of lower quality. The presented system opens a new door for quality control and material investigation, 40838
Eckelt, B.; Meyendorf, N.; Morgner, W.; Richter, U.
Use of automatic image processing for monitoring of welding processes and weld inspection Proceedings of the 12th World Conference on Non-Destructive Testing, Amsterdam (Netherlands) 23-28 Apr. 1989, Vol. 1, pp. 37-41. Edited by J. Boogaard and G.M. van Dijk, Elsevier, 1989 Advantageous incorporation of image processing into quality assurance in automatic welding is exemplified by thermography as well as flaw detection by radiography. The problem area of monitoring the temperature regime has been solved, permitting quality assurance of specified mechanical and process properties. Weld flaws are automatically detected and satisfactorily evaluated by
NDT International June 1990
means of radiographs. Work is in hand to improve the hardware and flaw classification as a function of the load conditions expected. 40722
Ahmed, T.; Feng, Z.J.; Kuo, P.K.; Hartikainen, J.; Jaarinen,
J. Characterization of plasma sprayed coatings using thermal wave infrared video imaging Journal of Nondestructive Evaluation, Vol. 6, No. 4, pp. 169-175 (1987) A pulsed (time-domain) thermal wave infrared video imaging technique, using an IR camera, a video image processor, and a flash lamp, is described. This system is applied to the imaging of interfacial defects in plasma sprayed coatings on metallic substrates. Results are compared with the conventional point-scanned cw infrared thermal wave imaging technique. 40511
Hitachi Construction Machinery Co., Ltd.
Supersonic flaw detecting system U.S. Patent No. 4,768,155 (30 Aug. 1988) A flaw detection system is described which uses supersonic waves. The object to be inspected is scanned relative to the supersonic emitter probe in two orthogonal directions. Receiver probes convert output to electrical signals which are used as image data for oscilloscope and television display screens. Image processing techniques are employed to manipulate the image memory created from output data. The operator can specify any position on the television monitor by means of the computer control system.
Anathanarayanan, T.S.; Rosemeier, R.G.; Mayo, W.E.; Sacks, S. 40468
Novel non-destructive X-ray technique for near-real time defect mapping Nondestructive Characterisation of Materials 2, Montreal (Canada), 21- 23 Jul, 1986. pp. 657-666. Edited by J.F. Bussiere, J.P. Monchalin, C.O. Ruud, R.E. Green Jr. Plenum Press, 1987 A novel x-ray technique is presented which offers the capability for near-real time defect mapping in a variety of electronic materials. The method relies on a recently developed computer controlled x-ray rocking curve analyzer which utilizes localized x-ray line broadening as a means of quantifying the local dislocation density. By the use of electronic x-ray detectors and image processing techniques, a high quality image of the defect distribution can be produced in a fraction of the time required for conventional x-ray topographs. Moreover, the system requires minimum operator intervention due to its microprocessor control, thus making it ideal as a powerful nondestructive tool for both QC and research applications. The operating principle of the system will be presented along with application to the study of defect distributions in a variety of substrate materials and epitaxial thin films. 40404
Stewart, D. G.
Automatic penetrant evaluation Non-Destructive Testing, Proceedings of the 4th E u r o p e a n Conference, London (United Kingdom), 13-17 Sep. 1987. Vol. 4, pp. 2801-2807. Edited by J.M. Farley and R.W. Nichols. Pergamon Press, 1988 There have been various attempts in the last decade to automate the visualisation and evaluation of fluorescent indications. The USAF, US Army and US Navy, in conjunction with the General Electric Company, started a major automatic inspection development programme called IBIS or Integrated Blade Inspection System. It included the automatic penetrant processing and inspection as a constituent part. The input of expertise in the areas of image processing and pattern recognition is noted. Including a manual 'bleed-back' stage. The enhanced repeatability of the automatic inspection system offers significant improvements in indication validation over human inspection. The need to apply non-linear algorithms in the evaluation of indications is also stressed. 40393
Zheng, Yi.
Image analysis, modeling, enhancement, restoration, feature extraction and their applications in nondestructive evaluation and radio astronomy Dissertation Abstracts International, Vol. 49, No. 2, pp. 507 (Aug. 1988) This dissertation is complied from nine papers and addresses itself to the development and application of signal and image processing to nondestructive evaluation (NDE) generally and to radio astronomy specifically. Topics covered include time series analysis and modeling of Very Large Array (VLA) phase data, image analysis, and feature extraction for industrial NDE radiographic images as well as image enhancement by Kalman filtering and considering signal dependent coloured noise. Robotic image manipulation, controlled by expert systems, is covered. Kalman filtered VLA phase data is studied using a supercomputer x ray and infrared images may be deblurred with the deconvolution method suggested. The last two papers cover local feature enhancement of synthetic radio images by adaptive Kalman filtering and a new technique for correcting phase data from a synthetic-aperture antenna array. 40329
Daum, W.; Heidt, H.; Rose, P.; Builtjes, J.H.
Real time evaluation of weld radiographs by digital image processing Proceedings of the 4th European Conference on Non-Destructive Testing, London (United Kingdom) 13-17 Sep. 1987. Vol. 3, pp. 1568-1574. Pergamon Press, 3173 pp. (1988).
169