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An overview of methods to detectAn overview of methods to detectAn overview of methods to detect composite/substrate bondingAn overview of methods to detect composite/substrate bonding

11/18/2011 1www.oceaneering.com

Donald McNicolDonald McNicol

Main methods

Main methodsMain methods

Ultrasonic

Radiographyg p y

Acoustic Impedance

Microwave

2

Ultrasonic

• Readily available• Data can be reported• Wide range of techniques• Can be automatedCan be automated• Data can be recorded• Minimal environmental/safety impact

Diffi lt t i l• Difficult materials• Difficult to interpret• Needs reflector• Needs couplant

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Radiography

• Provides clear image• Provides record• Well understood and accepted• Significant environmental/safety impactSignificant environmental/safety impact• Disruptive to work area• Significant training and regulatory requirement

Diffi lt t d t t ll d it h• Difficult to detect small density changes

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Acoustic impedance

• Bondmaster readily available• Track record• Provides good point data• Minimum environmental/safety impactMinimum environmental/safety impact• Needs physical disbond to operate • Data difficult to record

R i l t• Requires couplant• Very difficult to automate for area coverage

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Microwave inspection - agenda

1 Introduction1

2

Introduction

Theory overview

3 Application

4 Pros and cons

5 Summary

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Microwave inspection of non metallic materialsnon metallic materials

Materials• ThermoplasticsThermoplastics• Fiberglass piping and patches• Reinforced and non-reinforced rubber

C t• Concrete• Ceramic• Any other bulk dielectric/composite

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Detectable defects

• Delaminations• Disbonds

F i M t i l I l i• Foreign Material Inclusions• Voids• Changes in thickness• Moisture or liquid contamination• Mechanical damage• Physical changes due to chemical attackPhysical changes due to chemical attack

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Principle of operation

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Principle of operation

Material test pieces are bathed in Microwave Energy of a constant frequency. (Low GHz)

Different dielectric constants reflect varying levels of μW energy to a detector.

The energy level is sampled across the test piece and plotted to create an image.g

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Principle of operation

Microwaveemitter

Dete

Dete Reflector

emitter

ector A

ector Bwww.oceaneering.com 11

Detector output is in Volts

Data presentation

• Detector voltage A, B and C (A-B) at an X,Y position• Amplitude in Gray scale or Color• Data plot can be manipulated in quasi 3D

Physical Y

Detector Voltage (Z)

Physical X

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Equipment

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Deployment

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Example – Rubber expansion joint

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Example – Rubber expansion joint

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Example – HDPE pipe butt weld

HDPE Pipe WeldsShows Weld & Data

No Defect

Sand Inclusions

Grass Inclusion

Cold Joint Flaw

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Example – Fiberglass pipe coupon

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Example – Fiberglass “Clockspring” reinforcement

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Example – Fiberglass “Clockspring” reinforcement

Flaw AreasPoor Substrate Adhesion

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Example – “AquaWrap” reinforcement

Reinforcement applied over 4 rectangular air bags (approx 0.005 air g g ( ppgap) First (0.5” x 0.5’) applied to surface at 0 degree, second (1” x 1”) at 90 degrees, third (1” x 1”) obliquely at 180 degrees between layers 2 and 3 and fourth (1” x 1”) obliquely at 270 degreesfourth (1 x 1 ) obliquely at 270 degrees between layers 6 and 7 of 8.

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Example – “AquaWrap” reinforcement

0.5” Disbond at surface 1” Disbond between layers 2 and 3

1” Disbond at surface 1” Disbond between layers 6 and 71 Disbond at surface 1 Disbond between layers 6 and 7

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Example – Bondstrand GRP

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Example – GRP to GRP

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Example – GRP to GRP

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Example – GRP to GRP

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Microwave – application status

Current usage Proven application

• Body armour• Ceramic heat shields• HDPE gas distribution piping

•Subsea pipe and manifold insulation•Clockspring type re-enforcement•Piping insulation field jointsHDPE gas distribution piping

• Earthmover tyre rock detection• Rubber expansion joints in

nuclear power stations

p g j•Wind turbine blades•Marine sonar domes•Marine “stealth” material bondingnuclear power stations

• HDPE water pipe in nuclear power stations

• Composite laminate sheet

g•Aircraft composites•CUI•HDPE electro-fusion weldsp

manufacture• GRP water /chemical piping

•GRP and HDPE pipe internal erosion/degradation

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Microwave - pros and cons

• Inspect previously uninspectable • Inspect previously uninspectable materials !materials

• Locate and characterise defects that lead to mid to long term failure

materials !• Starting to be accepted• Restricted surface temperature

rangefailure• Automated• Data recorded• Fast

range• Topside, dry use only• Extensive training• Extensive experience• Fast

• System use restricted to qualified operators

• Recognised by some regulatory

• Extensive experience

Recognised by some regulatory bodies

• Broad range of applications

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ISO - Non Destructive Testing

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ISO - Non Destructive Testing

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Microwave - summary

• Microwave can detect and characterise irregularities that cannot be detected by other NDE techniques.

• Inspection speed and cost is comparable with Ultrasonic methodsN h d i i• No hazardous emissions

• No environmental impact• Major regulatory body approval in process

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