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This study aims to solve the problem of weld quality inspection, for the aluminum alloy profile welding structure of high-speed train body has complex internal shape and thin plate thickness (2–4 mm), the conventional nondestructive testing method of weld quality is difficult to implement.

In order to solve this problem, the ultrasonic creeping wave detection technology was proposed. The impact of the profile structure on the creeping wave detection was studied by designing profile structural test blocks and artificial simulation defect test blocks. The detection technology was used to test the actual welded test blocks, and compared with the results of X-ray test and destructive test (tensile test) to verify the accuracy of the ultrasonic creeping wave test results.

It is indicated that that X-ray has better effect on the inspection of porosities and incomplete penetration defects. However, due to special detection method and protection, the detection speed is slow, which cannot meet the requirements of field inspection of the welding structure of aluminum alloy thin-walled profile for high-speed train body. It can be used as an auxiliary detection method for a small number of sampling inspection. The ultrasonic creeping wave can be used to detect the incomplete penetration welds with the equivalent of 0.25 mm or more, the results of creeping wave detection correspond well with the actual incomplete penetration defects.

The results show that creeping wave detection results correspond well with the actual non-penetration defects and can be used for welding quality inspection of aluminum alloy thin-wall profile composite welding joints. It is recommended to use the echo amplitude of the 10 mm × 0.2 mm × 0.5 mm notch as the criterion for weld qualification.

This paper aims to provide an effective method so that the ultrasonic technique can be applied to the online debris particle detection. It proposes utilizing the waveshape features in discriminating the debris particle in lubricant.

The finite element model has been developed to investigate the scattering of the ultrasonic waves in lubricant containing single scatterer, such as the debris particle and the air bubble. The simulation results show that the results verify that different scatterers differ in the waveshape features. The static experiments were carried out on a specially fixture. The single spherical debris, long debris and air bubble were measured. The fast Fourier transform (FFT) method was applied to the analysis of the echo signals to obtain the features implicated in the waveshape.

The research of this paper verifies that different scatterers differ both in their shape features and in the FFT analysis features.

The rapid movement of the debris particles as well as the lubricant temperature may influence the measuring signals. Besides, the measuring signals are usually corrupted by noise, especially for the tiny debris. Therefore, researchers are encouraged to solve those problems further.

The paper includes implications for the improvement in the online debris detection and the development of the ultrasonic technique applied in online debris detection.

The paper provides a promising way that the ultrasonic waveshape features can be utilized to the identify debris particle online.

Describes the application of an ultrasonic sensing system for the non‐destructive inspection of welds as an alternative to X‐rays. Replacing radiography with ultrasound not only allows faster, more economical inspections but also eliminates the health and safety risks associated with radiography. In practical terms that means there is no need to evacuate the site for inspection purposes – construction work can continue, round the clock if necessary, thus dramatically reducing construction times.

As an advanced manufacturing method, additive manufacturing (AM) technology provides new possibilities for efficient production and design of parts. However, with the continuous expansion of the application of AM materials, subtractive processing has become one of the necessary steps to improve the accuracy and performance of parts. In this paper, the processing process of AM materials is discussed in depth, and the surface integrity problem caused by it is discussed.

Firstly, we listed and analyzed the characterization parameters of metal surface integrity and its influence on the performance of parts and then introduced the application of integrated processing of metal adding and subtracting materials and the influence of different processing forms on the surface integrity of parts. The surface of the trial-cut material is detected and analyzed, and the surface of the integrated processing of adding and subtracting materials is compared with that of the pure processing of reducing materials, so that the corresponding conclusions are obtained.

In this process, we also found some surface integrity problems, such as knife marks, residual stress and thermal effects. These problems may have a potential negative impact on the performance of the final parts. In processing, we can try to use other integrated processing technologies of adding and subtracting materials, try to combine various integrated processing technologies of adding and subtracting materials, or consider exploring more efficient AM technology to improve processing efficiency. We can also consider adopting production process optimization measures to reduce the processing cost of adding and subtracting materials.

With the gradual improvement of the requirements for the surface quality of parts in the production process and the in-depth implementation of sustainable manufacturing, the demand for integrated processing of metal addition and subtraction materials is likely to continue to grow in the future. By deeply understanding and studying the problems of material reduction and surface integrity of AM materials, we can better meet the challenges in the manufacturing process and improve the quality and performance of parts. This research is very important for promoting the development of manufacturing technology and achieving success in practical application.

An examination of the advantages of fail safe design and present non‐destructive testing techniques, and the importance of facilitating inspection at the design stage. THE introduction to this paper justifies in depth the case for fail safe philosophies in aircraft structural design. The advantages include improved safety, weight savings, the full availability of the potential fatigue life of each individual aircraft in the fleet, protection against accidental damage in service and manufacturing errors, together with a good resale value.

AT a manufacturing stage or to ensure the continued airworthiness of an aircraft's components, non‐destructive testing (NDT) occupies an important place in any inspection programme. By means of the methods employed, parts can be inspected and returned to service with confidence in their ability to fulfil a role in a system or structure. Also of significance is the early detection by NDT methods of potential defects so that preventative measures can be immediately implemented. This is particularly important where engine components are concerned in which high stress levels are part of the normal operating environment together with creep and fatigue in several forms.

Explains the use of non‐intrusive corrosion monitoring techniques at AEA Technology’s National Non‐Destructive Testing Centre. Outlines how non‐intrusive technology is now more widely accepted as it offers large cost savings, and examines its use on petrochemical tank floors, for scanning underwater and for providing a swift response.

The purpose of this paper is to present the results of acoustic emission (AE) and ultrasonic inspection of two H₂S storage tanks carried out in a heavy water plant, in order to characterize point type defects observed during earlier ultrasonic inspection and to ensure that these defects are not growing during hydrotesting of the tanks.

Using multiple AE sensors and AE source location methodology, the entire tank could be covered to detect and locate any dynamic sources of AE associated with local plastic deformation and/or growing discontinuities from any part of the tank during the hydrotest. For confirmation of the results obtained by AE, ultrasonic inspection on the tanks and on virgin plates from which the tanks were manufactured, were carried out.

The AE signals generated during first pressurisation are attributed to the micro yielding of the material of the tanks. A few scattered AE events were observed at a few locations during the hydrotesting of the tanks and these are due to structural and rubbing noise. During hold periods and repressurising cycle of the hydrotesting, no detectable AE events were observed and this confirmed the absence of any growing discontinuity in the tanks during the hydrotesting. Ultrasonic inspection on the tanks and on virgin plates confirmed that the point type defects detected are manufacturing defects and not formed during service life.

The combined results from AE and ultrasonic techniques confirmed the structural integrity of the tanks and ensured their healthiness for continued operation.

The paper brings out the use of AE and ultrasonic techniques for monitoring hydrotesting of storage tanks of a heavy water plant. The storage tanks where point type defect indications were reported during previous ultrasonic inspection and whether these defects are growing during hydrotesting of the tanks or not, were required to be known before the tanks are put in to further service. AE signals collected during pressurising and repressurising cycles of the hydrotest and subsequent inspection by ultrasonic confirmed the vessels to be free from growing defects during the hydrotest and provided baseline data for future inspection.

The purpose of this paper is to evaluate the application of an acoustic micro‐imaging (AMI) inspection technique in monitoring solder joints through lifetime performance and demonstrate the robustness of the monitoring through analysis of AMI data.

Accelerated thermal cycling (ATC) test data on a flip chip test board were collected through AMI imaging. Subsequently, informative features and parameters of solder joints in acoustic images were measured and analysed. Through analysing histogram distance, mean intensity and grey area of the solder joints in acoustic images, cracks between the solder bump and chip interface were tracked and monitored. The results are in accord with associated Finite Element (FE) prediction.

At defective bumps, the formation of a crack causes a larger acoustic impedance mismatch which provides a stronger ultrasound reflection. The intensity of solder joints in the acoustic image increase according to the level of damage during the ATC tests. By analysing the variation of intensity and area, solder joint fatigue failure was monitored. A failure distribution plot shows a normal distribution pattern, where corner joints have the lowest reliability and are more likely to fail first. A strong agreement between AMI monitoring test data and FE prediction was observed, demonstrating the feasibility of through lifetime monitoring of solder joints using AMI.

The paper indicates the feasibility of the novel application of AMI inspection to monitor solder joint through lifetime performance non‐destructively. Solder joints' real life conditions can be tracked by an AMI technique, hence solder joint fatigue failure cycles during the ATC tests can be monitored and analysed non‐destructively.

The purpose of this paper is to determine the feasibility of identifying the creep rupture of reactor cladding tubes using acoustic emission technique (AET).

The creep rupture tests were carried out by pressuring stainless steel capsules upto 6 MPa at room temperature and then heating continuously in a furnace upto rupture. The acoustic emission (AE) signals generated during the creep rupture tests were recorded using a 150 kHz resonant sensor and analysed using AE Win software.

When rupture occurs in the pressurized capsule tube representing the cladding tube, AE sensor attached to a waveguide captures the mechanical disturbance from the capsule and these data can be advantageously used to identify the creep rupture event of the cladding tube.

The creep rupture data of fuel clad tube is very important in design and for smooth operation of nuclear reactors without fuel pin failure in reactors.

AE is an advanced non-destructive evaluation technique. This technique has been successfully applied for on-line monitoring of creep rupture of the reactor cladding tube which otherwise could be detected by thermocouple readings only.