Augmented Reality is a Game-Changer for Nondestructive Testing
TL;DR
Problems: manual gridding of the parts and lack of spatial context of the inspection data.
Solutions: guided inspection in augmented reality with the scan results wrapped around the part.
Introduction
NDT is a valuable tool for ensuring the safety, reliability, and quality of materials and components. It is used to detect defects before they cause a failure, monitor the condition of materials over time, and ensure compliance with safety and regulatory standards. It is used in many industries, including Aerospace, Automotive, Construction, Energy, Manufacturing, Medical, and Utilities.
While the sensors used for various types of NDT are advanced and reliable the practices supporting the NDT process are still analog, slowing down obtaining the scan results considerably. Before scanning the surface technicians often need to grid it manually. During the scanning, results are encoded or mapped on the part with the wheel encoder, which is difficult or impossible in confined spaces.
Manual Gridding
Before conducting an inspection (e.g. A-scan or eddy current testing), technicians normally draw a 1-inch by 1-inch grid with the marker or chalk to keep track of the measurements. For the 40-inch pipes or large fuel tanks, this procedure could take as much time as performing measurements themselves. For aerospace panels mylar–a plastic stencil with round holes, is used.
Instead, the grid could be generated in augmented reality automatically and instantaneously. Once the probe is integrated, the readings could be displayed on the part in real-time to ensure that no measurement spots are missed.
Manual Mapping the Results / Encoding
Since the NDT probe knows nothing about the inspected part, a technician needs to make an additional effort to associate the measurements displayed on the screen with the actual surface. The encoder is sometimes used in addition to the probe. In the case of C-scan, when the part is curved, it may be particularly difficult to draw a correct map scanned area or reach it with the encoder.
Probe location could be tracked by the AR headset in real time and all the measurements could be aggregated directly onto the part. The part could scrubbed and measurements collected continuously. The heatmap or C-scan could be then overlaid for reinspection.
NDT Basics
Nondestructive testing (NDT) includes a wide range of analysis techniques used to evaluate the properties of a material, component, or system without causing damage.
It is also known as nondestructive evaluation (NDE), nondestructive inspection (NDI), and nondestructive examination (NDE). There are many different NDT methods, each with its own advantages and disadvantages. Some of the most common methods include:
- Visual inspection: This is the simplest and most common NDT method. It involves visually examining a material for surface defects such as cracks, corrosion, and wear.
- Ultrasonic testing: This method uses sound waves to create an image of the internal structure of a material. It can be used to detect defects such as cracks, voids, and thickness variations.
- Magnetic particle testing: This method uses magnetic fields to detect surface and near-surface cracks in ferromagnetic materials.
- Liquid penetrant testing: This method uses a liquid that seeps into cracks and other defects, and then a developer to make the defects visible.
- Eddy current testing: This method uses electromagnetic fields to detect surface and near-surface defects in conductive materials.
- Radiography: This method uses X-rays or gamma rays to create an image of the internal structure of a material. It can be used to detect defects such as cracks, voids, and inclusions.
