FIFTH CANADIAN CONFERENCE ON NONDESTRUCTIVE ... - IAEA

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ENTS LU LL o /IBER ID z 400 300 200 100 1 - 275 - _ 1 4 MATRIX FIBRE t r •) I / BEHAVIOR yr i BREAKAGE •- 20 tO 60 80 100 AMPLITUDE (dB) FIGURE 10 NON-ACCUMULATED AMPLITUDE DISTRIBUTION (LIN-LOG SCALE) FIGURE 11 BOOM FAILURE AT LOWER INSERT IN A DESTRUCTIVE TEST
- 276 - ACOUSTIC SORTING OF GRINDER BALLS F. Na.de.au. and J.F. Zixalnfin national Re.itax.ch Council o i Canada, Boucke.n.v±lle., Qntan-io An automated non destructive testing device for ball mill grinder balls was developed using acoustic flaw detection. An initial study of the sound generated in air by the impact of grinder balls has shown that the changes in ball velocity upon impact produce an initial low frequency pressure pulse and that various resonances exited in the impacted spheres produce the higher frequency oscillations that follow. Resonances of uncracked balls were related to a particular spheroidal mode of vibration while resonances of cracked balls are attributed to "tuning fork" modes of vibrations. Both a laboratory and an industrial prototype that perform the sorting of cracked and uncracked grinder balls using the differences in their acoustic properties were built and tested. A 97% success rate was achieved for 3" diameter balls. The device is being fitted to the production line. INTRODUCTION Many of the more sophisticated Non Destructive Testing (N.D.T.) techniques are expensive. This often restricts their use either to the aerospace or the nuclear industries. When an N.D.T. problem involves a low mark-up non critical product, emphasis is placed on the per unit cost of the test. Automation becomes important while 100% reliability is no longer required. This paper presents such an example where a cheap, fast, automated N.D.T. method was developed using audio range acoustics to detect flaws in grinder balls. Grinder balls are hardened steel balls used in stone grinding "ball mills". Those used in this study are forged from high carbon steel rods to roughly spherical shapes and waterquenched to a hardness of about 60 Re. A non négligeable proportion of the production exhibits deep running cracks and therefore tend to rupture under operating conditions inside the ball mill. This problem is familiar to ball mill operators who often have to manually remove the broken parts from inside the mill to ensure smooth operating conditions and prevent exercise wear of the mill's inner sleeve. Testing of the production is done on a statistical basis (samples of each batch) by manual inspection. Cracks can be detected visually and also acoustically: two balls are knocked together and a characteristic high pitch sound is heard if one of them is cracked. Acoustic, or "sonic" inspection is probably one of the oldest N.D.T. method. The sound of a body's natural resonances has been used to evaluate material properties (1, 2, 3), size and shape (4), and also for flaw detection (5). In the case of grinder balls, a study of the acoustical properties of good and cracked balls confirmed that repeatabledifferences in their natural sounds could be electronically detected. These results are presented in the first part of this article. An automatic grinder ball tester was designed and both a laboratory and an industrial prototype were built and tested. The second part of this article contains description of the laboratory machine along with some test results.
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q 11 Atomic Energy of Canada Limite
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ATOMIC ENERGY OF CANADA LIMITED FIF
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CINQUIEME CONFERENCE CANADIENNE SUR
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iii ACKNOWLEDGEMENT A special note
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DAY 2 KEYNOTE ADDRESS: Advanced Rad
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DAY1 KEYNOTE ADDRESS: Five Years Ex
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MB Power has a total generating cap
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The fourth lesson learned was that
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STATION UNIT Coleson Cove Coleson C
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0*'? - 8 - Ä | '••• '~-!.if~
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- 10 - 7/8 inch Titanium Tube 3D i
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The facility at CFB Greenwood was c
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CONDITION MONITORING - 14 - The Con
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- 16 - REDUCING UNWANTED EFFECTS ~
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- 18 - When this happens, the instr
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- 20 - (CJUIMTTCJW ROTOR BLADE SHOW
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- 22 - Un»hl«ld«d prob* - good b
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STEEL FASTENERS EXAMINATION OF FAST
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- 26 - SKIP FINNED TUHt •< IG 5 I
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To gain primary statistical informa
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- 30 - The next step in the develop
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Each firing of the capacitor banks
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- 34 - At the Bruce we have complet
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1 GARTER SPRING IN VERTICAL POSITIO
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DIGITAL READ OUT 3.595 TOIL ELEMENT
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- 40 - EVALUATION OF ULTRASONIC MET
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III MEASUREMENTS AND RESULTS - 42 -
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C Real defects - 44 - Here we repor
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Flaw Figure 1: Schematic of experim
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0.5 E10 Q. 8 1.5 2.0 - 48 - Positio
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- 50 - Figure 6: Optical micrograph
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- 52 - specialized applications suc
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- 54 - As the probed surface is not
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- 56 - in practice the central frin
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- 53 - bipolar pulse, as it is seen
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- 60 - 18. J.-P. Monchalln and R. H
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Sample Lens Ultrasound - 62 - Detec
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CD CO c O Q. W 0 - 64 - Sin(7TfuT)
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- 66 - AUTOMATED ULTRASONIC TESTING
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- 68 - 2.1 Scanning Bridge and Imme
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- 70 - each waveform digitization t
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- 72 - Further development of the s
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TRANSDUCER SELECT/ PULSE CONTROL -
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SCAIIIIING BRIDGE COLOUR GRAPHICS D
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Figure J — Beam profile of 3.5 MH
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- 80 - an additional reverse magnet
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- 82 - reinitialise the stress depe
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BAR MAGNET IDEAL FIELDS MEASURED FI
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- 86 - Figure 4: Hysteresis loops f
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-150 H= 1.6 kA/m COMPRESSION -100 -
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- 90 - MAGNETISATION ANHYSTERETÎC
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(b) 19 mm diameter o Hard spot 19mm
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Q. I CO zL 2 (Ky) TYPICAL UNCERTAIN
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- 96 - Figure 14: Conceptual M-H be
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- 98 - characterization program bas
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- 100 - 1. Planar transducer: l.a.
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Fig. 1 1/JS - 102 - Echos observed
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- 104 - CAPABILITIES/LIMITATIONS OF
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- 106 - V = f* - 0.9 ak N [2] h. /^
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DISCUSSION - 108 - The results of t
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- 110 - FIGURE 1: Equipment Used fo
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FIGURE 4: - 112 - 5 10 IS 10 Depth
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FIGURE 6: Output of Computer Modell
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- 116 - "Events on earth consist in
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- 118 - now _n = Af (5) n where Af
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- 120 - REFERENCES 1. J.K. Feiblema
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PULSER IMMERSION TRANSDUCER WATER ^
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- 124 - 6. Ultrasonic frequency spe
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i I 1 i l - 126 - —j 10. Ultrason
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TIME RNFOSIS PLOT CRSF: - 128 - 1H.
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- 130 - THE INTRODUCTION OF REAL-TI
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5. QUALIFYING THE IMAGE - 132 - In
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- 134 - CONVENTIONAL FILM RADIOGRAP
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- 136 - 11.3 Computer Management of
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- 138 - Back end of system. The com
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- IAO - to be loaded properly into
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20. OPERATIONAL UTILIZATION - 142 -
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% -•'v/ FILM AND SCREENS ' \ INSI
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- 146 - By design, these A/E monito
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- 148 - a) enables an A/E monitor s
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- 150 - OTHER . CHANNELS CONVENTION
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DAY 2 KEYNOTE ADDRESS: Advanced Rad
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- 152 - ADVANCED RADIOGRAPHY FOR TR
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- 154 - for light weight and resist
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- 156 - available. Application exam
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- 158 - 28. V.J. Orphan, Science Ap
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CROSS SLIDE - 160 - AXIAL DRIVE : 3
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- 162 - Fig. 4. Two neutron radiogr
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INTRODUCTION (Continued) - 164 - Pr
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- 166 - SENSITOMETRIC QUALITY CONTR
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- 168 - MAKING THE TRANSITION TO AU
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(Continued) - 170 - The primary mec
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UJNXKAST o Indicated: o Calculated:
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- 174 - F»LM_i5=l£B_ DATE22=22=ß
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- 176 - RECENT MICROFUCUS X~RAY IMA
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ABSTRACT - 178 - WET CHANNEL INSPEC
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- 180 - 5) an eddy current probe to
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- 182 - tube, say 0.5-1.0 metre, so
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ACKNOWLEDGEMENTS - 184 - Many peopl
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- 186 - TABLE 3 Operational Objecti
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Pressure Tube Fuel -Carter Spring S
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«AC UUSU«O«HII INCUMKTM - 190 -
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Inlet or Outlet £nd Outlet 2m - 19
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- 194 - AN ADVANCED HEAT EXCHANGER
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- 196 - storage terminal. However,
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2.4 Data Processing Subsystem 2.4.1
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- 200 - display parameter set could
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5. PLAYBACK - 202 - A tape playback
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" * 0 0 MOkE* i SUN! SOW A 1 3* ~V
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SLHHT POU 422/14 - 206 - x •* F-R
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- 208 - The recent failure of a Zir
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- 210 - probe in its operating envi
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- 212 - The eddy current and wall t
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6. SUMMARY - 214 - The failure of a
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+2.5%p Lift Off •* - 216 - +5% Wa
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0 -0.2 -0.4 -0.6 -0.8 -1.0 c .1 2 o
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0 -0.25 -0.50 -0.75 -1.00 -1.25 i 1
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- 222 - CHECKING FOR CRACKS IN GAS
Page 237 and 238: - 224 - on the fringes. (The sensit
Page 239 and 240: Figure 1 18 MW gas turbine rotor, p
Page 241 and 242: - 228 - Figure 3 Weak penetrant ind
Page 243 and 244: - 230 - Figure 7 All signals superi
Page 245 and 246: - 232 - Figure 11 Frequency respons
Page 247 and 248: - 234 - row 3 sent to 0 4 n 1Vor?d.
Page 249 and 250: 1. INTRODUCTION - 236 - In-service
Page 251 and 252: - 238 - treatment, and bending are
Page 253 and 254: - 240 - With an AC coil surrounding
Page 255 and 256: - 242 - against magnet position, tr
Page 257 and 258: 6. SUMMARY - 244 - Conventional edd
Page 259 and 260: 10 1 Centre Magnet 2 Keepers 3 End
Page 261 and 262: A - II' Concentric Groove 0.1 mm de
Page 263 and 264: - 250 ON THE RELATION BETWEEN ULTRA
Page 265 and 266: - 252 - Following a brief descripti
Page 267 and 268: CONCLUSION - 254 - In order to veri
Page 269 and 270: - 256 - 13. R.L. Smith, F.L. Rusbri
Page 271 and 272: Ultrasonic Instrumentation - 258 -
Page 273 and 274: 100 a (m" 1 ) 10 f Slope = 4 10 - 2
Page 275 and 276: - 262 - ACOUSTIC EMISSION TESTING O
Page 277 and 278: - 264 - Metal components with class
Page 279 and 280: - 266 - Any recognizable fibre dama
Page 281 and 282: - 268 - FIGURE 1 EXPULSION OF FIBRE
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Page 285 and 286: - 272 - FIGURE 6 SENSORS AND PREAMP
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Page 291 and 292: - 278 - 6e P = Po c - St or p = p0
Page 293 and 294: - 280 - (9) for hardened steel. All
Page 295 and 296: - 282 - but not reseted, so the com
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Page 299 and 300: 0 - 286 - Figure 5: Resonance frequ
Page 301 and 302: - 288 - GOOD 0 .8 1.6 2.4 3.2 Level
Page 303 and 304: - 290 - THE BENEFITS OF NDT TRAININ
Page 305 and 306: - 292 - C.S.N.D.T. Chapters continu
Page 307 and 308: - 294 - The groundwork is in place.
Page 309 and 310: - 296 - The graduates of these prog
Page 311 and 312: - 298 - CERTIFICATION OF NONDESTRUC
Page 313 and 314: - 300 - (e) A differing but persist
Page 315 and 316: 250 200 150 100 50 Magnetic Particl
Page 317 and 318: LOOKING INTO THE FUTURE R.S. Sh.an.
Page 319 and 320: - 305 - Another 'near future 1 need
Page 321 and 322: - 307 - NDE OF STRUCTURAL CERAMICS
Page 323 and 324: - 309 - The system described in thi
Page 325 and 326: and - 311 - S = a 2j for XR>a (2) S
Page 327 and 328: TRANSCEIVER digital signal display
Page 329 and 330: m "O -30 z o Ul -40 u. Ul ce o o Ü
Page 331 and 332: - 317 - deep penetration in same fo
Page 333 and 334: - 319 - the density by »w3 to 7%.
Page 335 and 336: density 10 3 kg/m 3 dissipation fac
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60 PZT7 Vp " - 325 - o A —polariz
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- 327 -
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- 329 - Fig. 8: Typical Outputs of
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- 331 - ULTRASONIC ANALYSIS OF VOID
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- 333 - function is approximated by
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PULSER/RECEIVER OSCILLOSCOPE SPECTR
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to •a I a. a Ê £ < IS i-o 00 -
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Figure 5: Frequency spectra from: (
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- 341 - 100 150 Void Diameter (jjm)
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- 343 - TIME (ns) Figure 9: Peak ti
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- 345 - COMPUTER SIMULATION OF ULTR
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pu = T XX + T Xy tt x y pV = T Xy +
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- 349 - linear system of equations
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- 351 - These boundary conditions a
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10. EXAMPLE - 353 - The following e
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3 "/A ! - 355 - 1 I 2 I Figs. 1-4.
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INTRODUCTION - 357 - The inspection
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- 359 - A 3 by k array was construc
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INVERSION PROBLEM - 361 - The inver
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- 363 - the right of coils 1 to 6,
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—- ••;•••• 'IM i lüi
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- 3hl 2 3 4 OISTANCE (mm) Figure h.
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- 369 - a) 0.080 X 0.010 X 0.004" 5
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- 371 - DISTANCE ;,n(m) Figure 9b
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- 373 - INTRODUCTION X-ray diffract
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and - 375 - e a -^(a + a ) + —-
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- 377 - The commercial prototype is
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- 379 - REFERENCES 1) Klug, H.P. an
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- 381 - incident x-ray beam diffrac
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- 383 - Fig. 5(a). 200 W X-ray tube
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- 385 - Fig. 7. Head of the commerc
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- 387 - APPLICATIONS OF NEUTRON DIF
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peaks which are easily measurable.
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- 391 - directions around the circu
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I.-3 TRIPLE-AXIS NEUTRON SPECTROMET
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Ad hki£ d hkil xlO 3 - 395 - INTER
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- 397 - Fig. 5 Longitudinal, tangen
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I - INTRODUCTION - 399 - Polyethyle
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- 401 - This together with the expr
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- 403 - (5v/v)fit must be considere
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Transducer Signal - 405 - P.E.(p.v)
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ü .CO ü m O o CÖ g •4—> Q 2.
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- 409 - The present study was carri
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- 411 - Since tomographlc Images ar
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- 413 - bore axis, were scanned. Th
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- 415 - normally measured with a sh
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(a) L (b) ic) 1 - 417 - •HwK- |3A
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Figure A : Orientation of the casti
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- 421 - APPENDIX A Determination of
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ÜJ I/) 1 ce TO PE/ a. 100 90 - 80
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- 425 - This paper will concentrate
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- 427 - Ultrasonic and radiographie
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- 429 - A micrograph of the laminat
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- 431 - 2. Holography requires disp
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- 433 - 10. Green, D.R., Schneller,
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- 4 35 - Fig. 2 (a): cross-section
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10 _ 0.1 1_ 0.01 0.1 1 - 437 - TIME
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• •' '
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HEATING PULSES DETECTOR " -—FILTE
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- 443 - 5 10 POSITION (mm) Fig. 10
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- 445 - MATERIALS EFFECTS ON ACOUST
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- 447 - orientation of these specim
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- 449 - determined experimentally f
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STRUCTURE •^ TRANSDUCER (S) - 451
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- 453 - 500 PRESSURE (KPO) LEAK DIA
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Caron, V. Energy Mines & Resources
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Mclntyre, Dent Babcock & Wilcox Can
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ISSN 0067-0367 To identify individu
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FIFTH CANADIAN CONFERENCE ON NONDESTRUCTIVE ... - IAEA

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