Roman Pinchuk

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Automatisierte Pfadplanung für robotergestützte Ultraschallprüfung von CFK-Komponenten mit komplexer Geometrie

Automatisierte Pfadplanung für robotergestützte Ultraschallprüfung von CFK-Komponenten mit komple... more

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Lunkerfest - Ermüdungsfestigkeitsnachweis auf Basis zerstörungsfreier Prüfungen an dickwandigen Eisengussbauteilen in der Windenergie : öffentlicher Schlussbericht zum Vorhaben

Robot-based In-Process Examination of ITER Dome and First-Wall Panels based on Novel Ultrasonic Tomography Approach

Manufacturing the components of International Thermonuclear Experimental Reactor (ITER) substitut... more Manufacturing the components of International Thermonuclear Experimental Reactor (ITER) substitutes a number of challenging material engineering tasks in respect to welding of specific bimetallic and trimetallic compounds. One of these tasks is the quality assurance of the weld joints after the manufacturing by hot isostatic pressing or explosion welding. Besides partially exotic material properties such as high sound velocity, coarse granulation, high sound attenuation and flaw orientations, these sandwich-lik e weld joints possess complex geometry, which makes testing them in-line along the manufacturing process challenging. Due to rather large dimensions an d high material thickness, no alternative NDE techniques can be considered for the non-destru ctive testing of these multi-layered structures. The state of the art of ultrasonic testing raises expectations concerning the quantitative imaging of material flaws with automatic on-line evaluation of i spection results, whereby a r...

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Efficient Characterization of Materials Using the Doppler Effect in Microwaves

A large number of microwave sensors are available on the market today. Unfortunately, sensors of ... more A large number of microwave sensors are available on the market today. Unfortunately, sensors of high quality are very expensive and tend to be stationary, making them unsuitable for integrating into an industrial process. Processing of microwave data is a challenging and complex task, and leads to high computational demands and increased processing time, so real-time quality control becomes virtually impossible. In this paper, we introduce a prototype system for nondestructive testing that utilizes moderately expensive continuous wave (CW) sensors. We exploit the physical phenomenon of the Doppler Effect to detect discontinuities in materials. We also propose an approach for fast measurements and data processing.

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Nondestructive and Contactless Materials Characterization with the Help of Microwave Sensors

With the help of microwave sensors it is possible to characterize nonconductive test objects in n... more With the help of microwave sensors it is possible to characterize nonconductive test objects in nondestructive and contactless manner concerning the materials properties like the permittivity and the correlated materials parameters like density or porosity. Since the specimen geometry influences the measuring quantities the specimen dimensions like thickness can be determined, too, if the materials properties remain constant. In the frame of experimental investigations the density of foam specimens made of polyurethane could be determined with phase sensitive microwave sensors working at the frequencies of 2.45 GHz and 5.8 GHz. By applying a pattern recognition procedure this is possible even if the distance between sensor and test object is changing. With a monolithic frequency modulated continuous wave (FMCW) radar sensor working in the millimetre wave range (94 GHz) the thickness of the anticorrosive plastics layer (polyethylene) on a steel pipeline is measured contactlessly. By ...

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Evaluating device, method and test system for testing of electrochemical cell assemblies

Evaluating device (10) for testing an electrochemical cell array (10), having the following featu... more Evaluating device (10) for testing an electrochemical cell array (10), having the following features: of test devices (a measuring data interface (12) for receiving at least two data sets that for an electro-chemical cell array (11) by means of at least two independent testers (22, 24, 32, 34) of a group 22, 24, 32, 34 ) are calculated and a total of several images of the electrochemical cell assembly (11) from different camera angles include, and a measurement data Fusionierer (14) which is formed, for each measurement data set of at least two data sets, a geometric model (16, 18) of the electrochemical cell assembly (11), which measurement data from the respective measuring data set comprises, on to determine the basis of several images from different camera angles and at least two geometric models (16, 18) to be combined to obtain a combined geometric model (20) with independently determined measurement data, wherein the set of test devices (22, 24, 32, 34) comprises an ultrasoni...

Method and device for the locally resolved recording and reconstructing objects using microwaves

Disclosed is a method and a device for the locally resolved recording and reconstructing objects ... more Disclosed is a method and a device for the locally resolved recording and reconstructing objects by means of microwaves, in which an object to be detected with microwaves is acted upon, at least, which are generated from a plurality of microwave antennas, and from the object reflected microwave components detected and converted into evaluatable microwave signals are made on the basis of an evaluation for spatially resolved object detection. The invention is characterized in that generating and detecting microwaves take place in the following manner: a) providing n microwave antenna units in spatial distribution around the object to be detected, b) selecting and activating a first microwave antenna unit for transmitting microwaves, c) receiving the reflected microwaves to the object with microwave antenna units m, with m ≦ n, and generating microwave signals, d) storing the microwave signals, e) selecting and activating another microwave antenna unit for emitting microwaves, and perf...

The Frequency-Domain Algorithm for Ultrasonic Imaging of Complex-Shaped Objects

Key Engineering Materials, 2018

The algorithms based on Synthetic Aperture Focusing Technique are aimed at the determination of t... more The algorithms based on Synthetic Aperture Focusing Technique are aimed at the determination of the imageries of the flaws in controlled objects. Ultrasonic imaging of complex-shaped objects requires specific algorithms which are able to take into account the complicated character of ultrasonic waves propagation. In this article, we suggested the novel frequency-domain algorithm for ultrasonic imaging of complex-shaped objects. This algorithm is based on Phase –shift migration theory and Stolt transform. The evaluation of suggested technique was done by the application of raw ultrasonic data which was obtained by using computer simulations. Derived results show that proposed algorithm is able to make accurate and precise imaging of flaws in complex-shaped objects.

Applying the Algorithm of Calculation in the Frequency Domain to Ultrasonic Tomography

Russian Journal of Nondestructive Testing, 2018

Applying ultrasonic-tomography systems makes it possible to precisely determine the shape and dim... more Applying ultrasonic-tomography systems makes it possible to precisely determine the shape and dimensions of flaws with the aim of establishing the degree to which the flaws influence safe operation of tested objects. This problem is solved by using special algorithms that make use of echo-signals recorded by an ultrasonic transducer to generate synthesized images of flaws in the sample. The use of phased arrays in ultrasonic tomography is explained by their ability to provide exhaustive data about the internal structure of a test object, thus allowing formation of the high-quality synthesized images of flaws in the object. Increasing the speed of ultrasonic tomography by using phased arrays necessitates the development and implementation of fast data-processing algorithms. In this connection, of interest are calculation algorithms in the frequency domain, which ensure the high speed of producing synthesized images. An ultrasonic-tomography algorithm is proposed that is based on calculations in the frequency domain. The algorithm takes the complex nature of the propagation of ultrasonic waves into account and is connected with the presence of media with different acoustic properties (e.g., in the case of immersion tests). Possibilities offered by the algorithm are investigated by computer simulations using the licensed CIVA 2016 software package and experimentally.

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Sampling phased array technology for the detection of voids in carbon fiber-reinforced plastics

The Journal of The Textile Institute, 2019

In the lightweight material industries, the current focus is on fiber-reinforced plastics, in par... more In the lightweight material industries, the current focus is on fiber-reinforced plastics, in particular on carbon fiber-reinforced plastics (CFRPs), since they offer higher relative specific tensile strength and stiffness as well as reduced weight compared to conventional metallic materials. Currently, the quality assurance of manufactured CFRP components represents a major challenge for CFRP manufacturers. Voids are generated during the infusion process of CFRPs, which in turn reduce the mechanical performance of CFRPs. This article presents the possibility to detect the distribution of voids across the surface of CFRPs by using a non-destructive testing method, the so-called sampling phased array ultrasound technology. Two types of CFRPs with six carbon layers in the same direction are fabricated by means of a vacuum-assisted resin infusion process. Voids in CFRPs are generated using a foaming agent during the impregnation process. The C-scan images produced through the sampling phased array technology are subsequently analyzed by the optical image analysis software in order to determine the amount of voids for each type of manufactured CFRP.

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Influence of defined amount of voids on the mechanical properties of carbon fiber‐reinforced plastics

Polymer Composites, 2018

The fault-free fabrication of fiber-reinforced plastics (FRPs) is a big hurdle for textile and co... more The fault-free fabrication of fiber-reinforced plastics (FRPs) is a big hurdle for textile and composite manufacturers. Voids are generated during the infiltration process of FRPs, which then reduce the mechanical performance of FRPs. This paper describes the effect of defined amount of voids on the mechanical properties, such as tensile, bending, impact and inter-laminar shear strength of FRPs. The defined amount of voids in carbon FRPs are produced by a newly developed process-mixing of a foaming agent with resin system during the infusion process. The utmost advantage of this process is simple, time-saving and reproducible. The produced FRPs from this process can be utilized for the validation of ultrasonic testing of FRPs. Four types of FRPs with six carbon layers are fabricated by a vacuum assisted resin infusion process. Carbon fibers are chosen in this study because of their growing market potential. Then, the mechanical properties of the produced carbon FRPs are tested. Besides the mechanical testing, the microscopic testing and ultrasound testing is executed to qualitatively analyze the length and distribution of produced voids. Results reveal that the mechanical properties of carbon FRPs reduce by an increase in defined amount of voids.

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Application of Fourier-Domain Post-Processing Technique for Ultrasonic Imaging with Matrix Phased Arrays in Advanced Manufacturing of Details and Machines

Materials Science Forum, 2018

Quality of the components in the mechanical engineering is of the utmost importance. Most of qual... more Quality of the components in the mechanical engineering is of the utmost importance. Most of quality control procedures can be provided by advanced quality assurance methods that enable visualization of inner structure of a component within all of the occurring defects. This paper suggests an innovative post-processing technique for Full-Matrix ultrasonic imaging with Matrix phased arrays in the case of immersion testing. Evaluation of the reliability was performed by simulation via CIVA software as well as by experimental testing of a real component with given defects. The obtained results of the research demonstrated high sensitivity and accuracy of the suggested technique.

Fourier-domain post-processing technique for Digital Focus Array imaging with Matrix phased array for ultrasonic testing of ITER components

Fusion Engineering and Design, 2018

The high demands on the quality of the components of the International Thermonuclear Experimental... more The high demands on the quality of the components of the International Thermonuclear Experimental Reactor (ITER) create the need to apply methods of nondestructive testing which are able to provide accurate and reliable results. One such technique is Digital Focus Array ultrasonic imaging with Matrix phased arrays. The application of this approach is linked with the need to process huge sets of data in order to obtain images of controlled objects. In this article, we propose the technique of computationally efficient Fourier-domain postprocessing. This algorithm is based on Fast Fourier transformations and calculations in frequency domains and can be applied in immersion and contact testing. The performance of this technique was examined experimentally.

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Principles of construction of ultrasonic tomographs for solution of problems of nondestructive testing in mechanical engineering

IOP Conference Series: Materials Science and Engineering, 2016

The paper considers the problems of ultrasonic nondestructive testing of products intended for me... more The paper considers the problems of ultrasonic nondestructive testing of products intended for mechanical engineering. The functional and electronic circuits of an ultrasonic tomograph are presented. The function of signal radiation from the clocked multielement apparatus is described, the cross-functional flowchart of the prototype of a US tomograph is considered. The development trends of ultrasonic tomography for near-term outlook are demonstrated.

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Frequency-domain imaging algorithm for ultrasonic testing by application of matrix phased arrays

MATEC Web of Conferences, 2017

Constantly increasing demand for high-performance materials and systems in aerospace industry req... more Constantly increasing demand for high-performance materials and systems in aerospace industry requires advanced methods of nondestructive testing. One of the most promising methods is ultrasonic imaging by using matrix phased arrays. This technique allows to create three-dimensional ultrasonic imaging with high lateral resolution. Further progress in matrix phased array ultrasonic testing is determined by the development of fast imaging algorithms. In this article imaging algorithm based on frequency domain calculations is proposed. This approach is computationally efficient in comparison with time domain algorithms. Performance of the proposed algorithm was tested via computer simulations for planar specimen with flat bottom holes.

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Verfahren und Vorrichtung zum ortsaufgel?sten Erfassen und Rekonstruieren von Objekten mittels Mikrowellen

Method and Device For The Spatially Resolved Detection and Reconstruction of ObjectsBy Means of Microwaves

Phase Statistics and Spectral Analysis of Ultrasonic Signals for CFRP Component Assessment

The established and industrially applied ultrasonic inspection and monitoring techniques typicall... more The established and industrially applied ultrasonic inspection and monitoring techniques typically use the amplitude values of the ultrasonic signals for assessment of flaws. However every individual signal value has the phase information, in addition to the amplitude information. Through analysis of the statistical distribution of phase values provided by state-of-the-art measurement systems and an appropriate consideration of this information in the signal evaluation, a significant improvement in flaw detection capability of an ultrasonic test can be achieved. Moreover, the phase and the frequency of ultrasonic signals carries information that can be correlated to the inner structure and existing inhomogenities of the material to be assessed. The two novel approaches for increasing the information content of the classic ultrasonic test-phase statistics and spectral analysis-are new and promising. Use of these approaches, even for on-line measurements has become possible particularly through modern computer science and signal processing. It is particularly significant that these methods are based exclusively on the analysis and processing of "conventionally" acquired ultrasonic signals, so that in-depth rework of the measurement technology or ultrasonic hardware can be added with additional useful information on the material's condition to be obtained.

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Dry Storage Casks Monitoring by Means of Ultrasonic Tomography

Physics Procedia, 2015

Spent nuclear fuel (SNF) is one of the most hazardous types of nuclear power plant waste. This fa... more Spent nuclear fuel (SNF) is one of the most hazardous types of nuclear power plant waste. This fact emphasizes the importance of careful handling and storage of SNF. There are two current state-of-the art technologies of SNF storage facility: wet and dry. It is important to mention that IAEA does not determine which kind of handling strategy should be chosen, however it is noted that dry storage of SNF could be used for one hundred years. Mining and Chemical Enterprise (MCE) is one of the leading Russian companies that deals exclusively with the dry storage of SNF. This company has implemented a long-term storage scheme. At the same time MCE faced the challenge of nondestructive monitoring of the degradation process of structural material of cask and its sealing with weld seam. Currently, X-ray testing is used for this purpose but in order to provide an effective nonradioactive method of monitoring MCE has initiated a collaborative R&D project with TPU supported by the Russian Government. Ultrasonic industrial tomography technique was proposed as the solution. The method is based on application of phased and sparse arrays transducer with real-time visualization algorithm. Received acoustic data is processed and realized by means of Sampling Phased Array technology which is a collaborative development of TPU and IDeal Technology, GmbH. The multichannel ultrasonic setup of immersion control was assembled for performing testing of seven experimental specimens with representative defects (side drill-holes, notches, natural welding flaws). X-ray tomography of high-resolution was chosen as the reference method. All indications were successfully reconstructed in B and C-scans and 3D image. The next step is to automate the monitoring procedure completely and to introduce an evaluation tool for current flaw state and prediction of its further behavior.

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Stand-off detection of suspicious concealed objects in centimetreand millimetre-wave range using sampling phased array principle and sparse array

In the area of Homeland Security the concept for a novel imaging system for detection of dangerou... more In the area of Homeland Security the concept for a novel imaging system for detection of dangerous and illicit objects concealed under clothes of humans under motion is presented. It is based on innocuous electromagnetic waves in cm- and mm-wave range. Principles to be used comprise synthetic aperture to increase lateral resolution, polarization to enhance object separation as well as sampling phased array and sparse array to reduce the number of needed antennas. To reach real time capability techniques like parallel processing, FPGAÂ¿s, graphic processing units and look-up tables will be applied.

Roman Pinchuk

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