progress of digital industrial radiology · outside incorporated metal mesh central section in...
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Progress in Digital Radiology EwertApril 2007
Progress of Digital Industrial Radiology
byUwe Ewert
[email protected]://www.bam.de
[email protected]://www.bam.de
INDE 2007India, Chennai, April 25th , 2007
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Progress in Digital Radiology EwertApril 2007
• Film replacement• Computed Radiography (CR) with phosphor imaging plates – High
Definition Computed Radiography (HD CR)• Digital Detector Arrays (DDA)
• High Contrast Sensitivity Radiography with DDAs• Automated Defect recognition
• Dual energy technique• X-ray back scatter technique (BS RT)• X-Ray Modeling and POD• Portable Computed Tomography for
• Nuclear power plants• Large flat components in Aircraft industry
• Small angle scatter CT and nano CT at Synchrotron• Motion neutron - radiography
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Film Replacement
Computed Radiography (CR) with phosphor imaging plates – high definition CR
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Reporting
Archive
Networking
Digital Detector Arrays
Film Digitizer
ImagingPlates
Data TransmissionScannerfor Imaging Plates
Hard CopyGrayscalePrinter Agfa
INDO-GERMAN Workshop on DIR 1999
Computed RadiographyStandards available now
Radiology with Digital Detector Arrays
Graph of:
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Motivation for Film Replacement by Computed Radiography and DDA‘s
Motivation for Film Replacement by Computed Radiography and DDA‘s
• Shorter test and interpretation time
• New application areas by higher inspection quality and wall thickness range
• No chemicals and dangerous waste
• Less consumables
Film (D4)
Flachdetektor (Hamamatsu)
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Filmless Radiography
Computed Radiography withPhosphor Imaging Plates
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The Imaging Plate CycleThe Imaging Plate Cycle
Exposure of Imaging Plate
Imaging Plate
Cassette
Lead filter
Exposure
Scanning the IP , Digitising and Erasing the residual Image
Processing Station
INDO-GERMAN Workshop on DIR 1999
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Radiography (CR) with Phosphor Imaging PlatesASME CR Code Case 2476
First digital catalogue, light alloy castingdigitized films from ASTM E 155 (BAM)
ASTM E 2422
DDA under developmentASTM E 07
Part 1: Classification of Systems, Part 2: General principles
EN 14784 CR
RadioscopyEN 13068
Film DigitisationEN 14096, ISO 14096
Classification (E 2446), Long term stability (E2445), Guide (E 2007), Practice (E 2033)
ASTM CR
New Standards on Digital Industrial Radiology
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EN 14784-2
System Selection
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Filmless Radiography
CR Applications
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High Definition CR Systems for Welding
HD CR:„VistaScan“, of Duerr, Germany
FUJI IP‘s, light blue
Systems available down to• 12 µm pixel pitch and • < 40 µm unsharpness
• “weld quality”
BAM 5: 8 mm steel
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•36 inch 12.7 mm Wall thickness Pipe Weld (SWSI-panoramic exposure )
Digital Radiography for Pipeline Testing
FilmFree meeting17.04.2007
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f = film focus distancer = outer pipe radiusR = outer radius of insulationw = projection of wall thickness
w on the detector planeVEBA-OEL 2000
Corrosion and Wall Thickness Measurement:Corrosion and Wall Thickness Measurement:
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Wall Thickness MeasurementWall Thickness Measurement
Tangential Radiographic Technique(TRT)
Tutorial at 24.04.2007INDE2007, Chennai
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High Energy X-Ray Inspection in Lieu of Manual Maintenance Check of Large Components
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Filmless Radiography
Flat Panel Detectorsand the new
High Contrast Sensitivity TechniqueHCS-RT
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New Flat-Panel Detector TechnologyNew Flat-Panel Detector Technology
Spahn 97
New DevelopmentsNew Developments
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SNRnorm
Current limit of film and CR technology
SNR limit by materials structure
High Contrast Sensitivity TechniqueEffect of Correct Calibration Procedures
DDAs exceed film quality!
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Film and Flat Panel Detector for the BAM 5 Weld.
ASTM E2002 duplex wireASTM E1025 Inconel5 Hole Penetrameter
ASTM E747 / EN 462-2Fe 13 Wire Penetrameter
EN 462-2 Step Hole Type IQI „H1“
BAM 5 is a hand welded steel plate (St 35) 8 mm thick, the welding seam is max. 10 mm thick. It contains all types of welding flaws, especially nice cracks at the surface of the welding seam.
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Fuji IX25SNRnorm~ 265
PerkinElmer 1620SNRnorm~ 1500
by K. Bavendiek et all.
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Fast Test of Heat Exchangerswith
Tiled DDA
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WLE/AD - Plant Inspection, Welding Engineering; PVT Meeting Freeport 2004 14
RT-testing of tube-to-tube-sheet jointsGammat B3
Ir 192, Radiator: 1 x 0.5 mm²
Possible tube dimensions: 12*1.5 up to 76.1*4 (diameter*thickness)Materials: carbon and stainless steel, Ni-alloys, Zr, (Ti, Ta)Joint design shall be considered
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X-ray tube Warrikhoff MCTS 130A-0,6 and CdTe-Detector Ajat DIC100TH
Practice test:
Testing of Heat Exchanger Weldswith a specialised Digital Detector ArrayThrough the Detector
Testing of Heat Exchanger Weldswith a specialised Digital Detector ArrayThrough the Detector
Alekseychuk, Zscherpel, Rost
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D4 film with 130 kV:1 min (1mm Sn filter)
X-Ray tube with DIC100TH detector75 kV, 0,5 mA, 10s
Research-Project BASF/Ajat/BAM since 2006, first results on test weld
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Imaging and Materials Characterisation
with
Dual Energy Technique
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Explosive Detection by Dual-Energy-RadiologyExplosive Detection by Dual-Energy-Radiology
Baggage-transport
Typical device for explosive detection of baggage and fin postal service
(Smiths Heimann)
Smiths Heimann
Fan beams at two different energies
L-line detectors
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Dual-Energy-Technique for Plastics and Composite PipesDual-Energy-Technique for
Plastics and Composite Pipes
Inspection of a multi layer pipe, made from different plastics and with partial glass fibre reinforcement for chemical industry
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X-Ray Back Scatter Techniquefor
Security and Aircraft Industry
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X-ray Back Scatter Technique:
- Advantage is the single sided access
- Comscan – Technique was too slow and was applied only in very few areas
- New evaluation of back scatter technique due to the success in the security field
- New technologies are under development, e.g. in aircraft industry
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X-Ray Back Scatter Techniquewith single sided access
X-Ray Back Scatter Techniquewith single sided access
AS&E
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X-Ray Back Scatter Techniquewith Single Sided AccessX-Ray Back Scatter Techniquewith Single Sided Access
Organic materials are visible with high contrast
Flying Spot Unit
AS&E
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X-Ray Back Scatter Technique
Source: http://www.as-e.com Accepted e.g. in UK on voluntary basis
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Backscatter image of a personSource: http://www.as-e.com
Not accepted due to European Radiation Safety Regulations
1 µRem = 0,01 µSv
Radiation protection permits:1 mSv/year (100 mRem/year)for population but not without justification!
X-Ray Back Scatter Technique
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X-Ray Back Scatter – Flying Spot TechniqueX-Ray Back Scatter – Flying Spot Technique
Letter bomb dummy
Lange, Hentschel, BAM
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Terahertz (THz): Letter Bomb DummyTerahertz (THz): Letter Bomb DummyX- ray image
THz-Image
Kupsch, Lange, Beckmann,Hentschel
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Back Scatter Technique with specialized DiaphragmBack Scatter Technique with specialized Diaphragm
Diaphragm
Imaging plate/Detector Array
Shielding box
Camera
X-ray tube
Osterloh01/2007
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Fast Back Scatter Technique with Specialized DiaphragmFast Back Scatter Technique with Specialized Diaphragm
Water in Honeycomb
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Water in Honeycomb-StructuresWater in Honeycomb-Structures
Radiograph
Back scatter image Planar-tomogram
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Detector
Collimator
Backscattersystem of InnospeXion
New Equipment
Combination of
• High sensitive DDA and
• Specialised collimator
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X-Ray Modeling for- Film replacement
- Planning of testing
- POD
X-Ray Modeling for- Film replacement
- Planning of testing
- POD
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Modelling ToolsModelling Tools
Surface presentation • Interface to CAD and CT• Separation of homogeneous regions• Arrangement of different Polygons in the virtual scene
Processes:• Absorption• Compton-Scatter / Rayleigh-Scatter• Interaction by Collision probability
m>0
m=0
s1
s2
s3object
detector
(E0,W0)
Source
Object
Detector
Jaenisch, Bellon
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Complex Geometry: Cardan jointSimulation-Example
Pore
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Surface scan @ BAM VIII.1
• Strip projection
→ →
• ATOS 3D Digitizer (www.gom.com)Flexible optical measurement device Is based on Triangulation3D-Coordinaten are calculateda Polygon net of the surface is generated (STL)
ATOS II
Measurement and Radiographic Modelling of CAD-Surface Images
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Result: 3D CAD Model of a weld• STL of “BAM 3”
Modelling of a Scanned Weldment
top
root
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Pore Contrast Considering Measured Unsharpness and Noise for POD Calculation
0.0 0.5 1.0 1.5 2.0 2.5 3.0pore diameter [mm]
0
200
400
600
800
1000
max
imum
por
e co
ntra
st
â versus a from Simulation
max pore contrast (no noise)above (noise level = 30)center (noise level = 60)below (noise level = 90)decision threshold (SNR = 2.7)
Simulation of contrast function for copper welds of different thickness
Required for copper storage containers of the Swedish final repository of nuclear waste fuels
Measured with 9 MeV LINAC undBIR-line camera
Modelling BasedPOD
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0.0 0.5 1.0 1.5 2.0 2.5 3.0pore diameter [mm]
0.0
0.1
0.2
0.3
0.4
0.5
0.6
0.7
0.8
0.9
1.0
PO
D m
ax c
ontra
st
Conservative POD Estimate from Simulation
SNR = 2.7POD (above)confidence boundPOD (center)confidence boundPOD (below)confidence bound
POD for Different Wall Thickness
Modelling BasedPOD
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Mobile CTin
Nuclear Power Plants and
in Aircraft Industry
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• Movement of X-ray tube parallel to pipe axis• Acquisition of few hundred projections• Reconstruction of cross sections
• Movement of X-ray tube parallel to pipe axis• Acquisition of few hundred projections• Reconstruction of cross sections
X-ray tube
Digital detector array
Planar Tomography – Reconstruction of Cross sections
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from outside to inside
3D-Reconstruction of Weldments Metallography
Planar Tomography
8
Certification byEuropeanNetworl ofInspection andQualification.
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Mobile TomosynthesisMobile Tomosynthesis
CT of Large ComponentsCT of Large Components
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Planar Tomography
Stringer Component from Aircraft
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Outside incorporated metal mesh
Central section in stringer
Inner surface with carbon fibre mesh
Impact
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Nano CT
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Berlin Electron Storage SYnchrotronBESSY
Double-MultilayerMono chromator, 5-70 keV7T WLS
asymmetricSi -Crystal,
Magnification 1: 50
CCD-Camera
rotatingSample
Storage ring
1 mm
3D-Nano-CT: Micro-driller, 19 keV, Worm holes, white refraction contrast,200 nm resolution
3D-Scatter CT: Ti/SiC-MMC, 39 keV,
light: crack contrast after fatigue
3D-CT-single cut
Gas turbine
Müller, Lange, Hentschel
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Motion Neutron Radiographywith Triggered Cycle
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BMW-Engine of running production with external electric control at ILL in Grenoble
T. Bücherl, B. Schillinger
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Oil cooling of pistons of running engine!
Oil at piston bottom
Oil ray is injected from downside to the piston
Valves(one after the other)
T. Bücherl, B. Schillinger
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Computed Radiography with Phosphor Imaging Plates is gaining more and more importance for mobile inspection and Film Replacement. New High Definition CR (HD CR) systems allow the CR application for Weld and Casting inspection with low energy X-rays. New calibration methods enable the High Contrast Sensitivity Technology(HCS RT) for radiographic inspection. The contrast sensitivity can be enhanced by a factor of 10 in comparison to film. New Digital Detector Arrays (DDA) are now available for stationary and mobile testing. They are also applied for automated defect recognition (ADR), CT, Back Scatter and Dual Energy Applications.Back Scatter Techniques are increasingly applied for Security and NDTNumeric Radiographic Modelling is applied for Experiment Planning, Film replacement, POD-calculations and trainingMobile and portable CT devices are suitable for non destructive cross sectioning in nuclear power industry and aircraft applicationsNeutron radiography at research reactors was enhanced for visualisation of motions
Summary:Summary:
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Acknowledgement
B. Redmer – BAM Berlin
U. Zscherpel – BAM Berlin
A. Alekseychuk – BAM Berlin
K. Bavendiek – Yxlon Hamburg
K. Osterloh – BAM Berlin
G.-R. Jaenisch – BAM Berlin
C. Bellon – BAM Berlin
M. Hentschel – BAM Berlin
A. Lange – BAM Berlin
J. Beckmann – BAM Berlin
Ch. Müller – BAM Berlin
S. Sood – CIT London
T. Bücherl – TUM Munich
B. Schillinger – TUM-Tech Munich
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Ende
e-mail: [email protected]://www.bam.de
e-mail: [email protected]://www.bam.de
BAM-Berlin, Lab. VIII.3Unter den Eichen 8712005 BerlinTel. (030) 81041831FAX (030) 811 5089
BAM-Berlin, Lab. VIII.3Unter den Eichen 8712005 BerlinTel. (030) 81041831FAX (030) 811 5089
BAMmain building