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Ultrasonic inspection
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Proceedings Papers
João Paulo Gabre Ferreira, Karen Juliana Vanat, Luciano Augusto Lourençato, Anderson Geraldo Marenda Pukasiewicz, André Ricardo Capra ...
ITSC 2015, Thermal Spray 2015: Proceedings from the International Thermal Spray Conference, 1128-1133, May 11–14, 2015,
Abstract
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Ceramic coatings are applied in mechanical components subject to high temperature conditions, normally are deposited by plasma thermal spraying process. In this work, the porosity of YSZ ceramic coatings, deposited with different parameters conditions were analyzed by optical microscopy, scanning electron microscopy using back-scatter electron (SEM-BSE) detector and ultrasonic technique. It was verified that porosity measurement by optical and scanning electron microscopy is very sensitive with respect to metallographic preparation, mainly cutting process, and gray level adjustment. SEM-BSE technique showed less scatter results with easier porosity visualization, compared with optical microscopy. The porosity of the coatings was also measured by ultrasonic technique. It was observed that the ultrasonic velocity increase with porosity reduction. Ultrasound technique showed a good correlation with OM and SEM porosity measurement.
Proceedings Papers
ITSC2012, Thermal Spray 2012: Proceedings from the International Thermal Spray Conference, 357-362, May 21–24, 2012,
Abstract
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To fully understand particle interactions with both substrate and neighboring particles in cold spray, ultrasound wave generation and ultrasonic monitoring of particle impacts were studied. The multi–channel ultrasonic system works in pulse– echo and passive modes. In pauses between pulse–echo data acquisition frames the system is in the passive mode receiving the signals generated by the particle impacts. The particles being deposited generate the ultrasonic signals in a very wideband frequency range at more than 40 dB signal-to-noise ratio. The particle impact signals are considered as a sum of the background wideband noise and the sparse strong pulses observed when the nozzle passes over the location of the transducer. It was shown that these components of the particle impact signal can be separated by threshold processing. The results of the passive monitoring are confirmed by the ultrasonic pulse–echo and direct measurements of a deposited coating geometry.
Proceedings Papers
ITSC 2006, Thermal Spray 2006: Proceedings from the International Thermal Spray Conference, 1039-1044, May 15–18, 2006,
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The studying of splats in thermal spray is prominent to improve coating properties due to better understanding of coating build-up mechanisms. Most of studies, however, devoted to splats rest on physical aspects of the build-up, which feature the behaviour of a single particle impinging on a substrate. These studies involve the nature, velocity and intrinsic characteristics of the particle. The present work deals with the study of the splat-substrate interface using an ultra-sonic (U.S.) technique. This technique is based on the determining of splat-substrate adhesion (for an elementary splat or a group of splats) to help in the optimising of spraying conditions. APS copper splats were studied for Al-based substrates. This U.S. technique was already tested successfully for adhesion control of thermally-sprayed coatings in Basel, Switzerland. Further development then related to the specific experimental set-up for splat analysis using several transducers. This involved the use of various frequencies, various sizes for the focal spot and various scan velocities. In this study, results from this U.S. technique were discussed in the light of the observation of cross-sections of U.S.- controlled splats. U.S. C-Scan images were shown to fit well with cross-sectional images. In a general conclusion, the work showed the feasibility and efficiency of advanced U.S. control of splats to promote thermally-sprayed coatings whatever the process, i.e. plasma spray, flame spray, HVOF or cold spray.
Proceedings Papers
ITSC 2005, Thermal Spray 2005: Proceedings from the International Thermal Spray Conference, 1041-1046, May 2–4, 2005,
Abstract
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The present work deals with the application to actual in industrial conditions of the promising results of the study on adhesion, as presented at the previous edition of ITSC’2004 in Osaka, Japan. These industrial parts were typical of those produced in workshops for aircraft-aerospace, petro-chemical, printing works industries etc…. Thermal spray processing of industrial parts tested in this study are numerous, primarily air plasma spraying (APS), HVOF and conventional flame spray with or without remelting. Ultrasonic NDT facilities are now installed in an actual industrial workshop and show the reliability of the testing method and related results. For every tested part, digital ultrasonic testing was carried out to be compared to results from conventional adhesion tests according to EN 582 standard. U.T. results were quite in keeping with those from EN 582 testing. However, in addition, ultrasonic testing exhibited the any heterogeneity when existing, (local weak zones) at the coating-substrate interface. This resulted in easy discriminating of adhesive areas from cohesive areas. Results of this work obtained in a real workshop environment leaves promising expectations for ultrasonic testing to meet results from conventional EN 582 adhesion testing when applied to industrially-produced parts. Ultrasonic testing results in a low-cost NDT method which should compete with current high-cost control. Moreover, ultrasonic NDT looks more reliable in so far as the whole part can be controlled due to scanning of the whole surface.
Proceedings Papers
ITSC1998, Thermal Spray 1998: Proceedings from the International Thermal Spray Conference, 843-848, May 25–29, 1998,
Abstract
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This study evaluates a nondestructive method for determining the adhesion strength and porosity of thermally sprayed coatings. The method is based on ultrasonic surface echo measurements. Porosity is surmised by the impedance of the coating and adhesion by the transmission coefficient. Experimental results confirmed that the method is effective for its intended use.
Proceedings Papers
ITSC1996, Thermal Spray 1996: Proceedings from the National Thermal Spray Conference, 947-951, October 7–11, 1996,
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Nondestructive methods previously developed for the detection of flaws, such as delaminations, or for the evaluation of the elastic properties of materials, could be judiciously adapted in order to get a better assessment of plasma-sprayed coatings. Laser ultrasonics is a nondestructive evaluation method which relies on both optics and ultrasonics. A short-pulse laser generates an ultrasonic wave into the material to be inspected, and a long-pulse laser, coupled to an interferometer, detects the resulting ultrasonic displacement. Laser ultrasonics is a remote sensing method and therefore could be used for the monitoring of hot plasma-sprayed coatings during the deposition process. In this work, experiments were performed on samples composed of ZrO 2 sprayed under different conditions onto thick copper substrates. The samples were first probed by conventional ultrasonic transducers and then by a non contact laser-ultrasonic scanning system. The two series of measurements agreed well. These experiments showed that, after calibration, the coating thickness could be measured during the deposition process, with a relatively good accuracy, by laser ultrasonics. The laser-ultrasonic scanning system also revealed non uniformity of more than 10% in the coating thickness of the tested samples. This thickness variation is possibly caused by a temperature gradient induced in the coatings during spraying.