Table of Content
- Futurescope of NDT Testing
- Emerging Technologies in NDT
- Potential Use of NDT in Uninhabitable And Hazardous Environments
- Robotics in Non-Destructive Testing
For decades, Non-destructive Testing (NDT) has ensured the safety and integrity of structures, machinery, and materials across various industries. Emerging technologies and changing trends have driven remarkable advancements in NDT technology.
NDT employs a range of techniques to evaluate the properties of materials, components, and structures without causing any damage, which has been the driving force behind its acceptance and growth over the years.
What Is the Futurescope of NDT/NDE Testing in the Future?
The 21st century has led to the origin of the Fourth Industrial Revolution or 4IR. This industrial transition has adopted automation, optimisation, improved data management, communication, and connectivity between processes. Human involvement is hence reduced, and systems are encouraged to automate maintenance, monitoring, troubleshooting, and general operation using advanced software resources, sensors, embedded systems, the Internet of Things (IoT), Artificial Intelligence, and machine learning.
The vast data obtained in making manufacturing processes and factories ‘smart’ provide active control of the process and machinery and can predict potential failures and maintenance requirements with the aforementioned resources. Automated value chain mapping enables efficient production, operation, and flexibility in systems, which allows customisation, and precision.
Industry 4.0 also focuses on data transparency by collaborating the operational data of the enterprise with the factory floor analytics. Non-destructive Testing Methods have become a focal point for the advent of Industry 4.0. Improvement of existing technology involves adopting embedded systems, advanced sensors, cloud computing for data storage and access, and artificial intelligence for improved analytics, error-free inference, coordinated process flow, and efficient troubleshooting.
Advanced techniques help with clearing the obstructions created by complicated Non-destructive Systems which require a deep understanding of the process, specific training, and significant experience on the operator’s part. Automation and Artificial Intelligence generalise processes and analyse trends in the operation to gauge and estimate the most convenient plan of action. The probability of human error from manual positioning, assembly, and installation is also minimised or eliminated using modern sensors. Workflows are streamlined by reducing iterations required to obtain accurate and standardised readings per industry standards.
Data interpretation is also streamlined and automated by using modern Non-destructive Technologies, hence avoiding recording and evaluation errors. Procedural data is meticulously documented, helping detect workflow and potential deviations from the standard procedure using these technical upgrades. Automation and cloud storage provide organisational access to testing data and reduce the time consumed in data processing and communication across the organisation.
It also provides data encryption for security, post-analysis data inspection, and quick access to old test results. NDT is beneficial to many industries, for testing a variety of materials and is viable for a variety of working environments, hence the field is consistently subject to extensive research and development.
Emerging Technologies in NDT
Emerging technologies in NDT include artificial intelligence, robotics, and advanced sensors that are revolutionising the way inspections are conducted. These technologies offer increased accuracy, efficiency, and safety in NDT Testing Procedures.
1. Advanced Sensors and Instrumentation
With the advent of advanced sensors and instrumentation, NDT is witnessing a paradigm shift. Sensors equipped with cutting-edge technologies such as Internet of Things connectivity, artificial intelligence, and machine learning algorithms enable real-time monitoring and analysis of assets, leading to proactive maintenance strategies.
2. Robotics and Automation
Robotics and automation are revolutionising NDT Inspection Technology by enhancing inspection capabilities and efficiency. Autonomous drones, crawlers, and robotic arms equipped with NDT sensors can navigate complex environments and perform inspections with unparalleled precision, minimising human intervention and ensuring safety in hazardous conditions.
3. 3D Printing and Additive Manufacturing
The widespread adoption of 3D printing and additive manufacturing techniques has created new challenges for NDT technologies. New non-destructive testing technologies are being developed specifically for additive manufacturing parts. These methods can find flaws like holes, cracks, and delamination even in parts with complicated shapes.
4. Augmented Reality (AR) and Virtual Reality (VR)
AR and VR technologies are revolutionising the way NDT inspections are conducted and interpreted. Immersive visualisation tools enable inspectors to overlay digital data onto physical assets, facilitating real-time analysis and decision-making. Moreover, Augmented Reality-based training simulations enhance the Skills of NDT Professionals, ensuring proficiency in complex inspection tasks. Using AR and VR in non-destructive testing technology will compensate for many limitations that have hindered progress in this field.
Get More Information About, Top Emerging Technologies in 2024
The Potential of NDT In Uninhabitable and Hazardous Environments
NDT provides a myriad of relatively simple techniques to automate and integrate with robotic systems. Mobile non-destructive testing technology uses advanced movement patterns and sensors to access structures and machinery in treacherous and hazardous environments.
These technologies save human involvement and risk to human life in dangerous situations while maintaining testing standards and ensuring the structural integrity of test subjects. Non-destructive technologies that can be automated include Visual Inspection, Ultrasonic Testing, Phased Array Ultrasonic Testing, Time of flight diffraction, and Eddy Current Inspection.
Choose the right path: Explore destructive vs non-destructive testing
NDT Techniques can be used in the following environments:
1. Chemically hazardous work environments
Extended exposure to chemicals in a workplace may cause workers long-term and fatal illnesses. Multiple industry standards are set in place regarding chemical exposure limitation, chemical safety protocols, and occupational gear for workers. NDT technology advancements like robots and machinery are replaceable, unlike human life and safety, hence chemical-resistant robots can be used, in conjunction with NDT apparatus.
2. Work environments with particulate pollution in the air
Particulate matter suspended in the air can be inhaled and ingested by workers, causing severe organ damage (including lungs, heart, and bones). Dust may include lead, cement, silica, wood, flour, mold, etc. Robots, on the other hand, may fit with sensors (IP65) and be made dustproof. Non-destructive examination technology operating through robots protects human workers from hazardous working conditions and long-term issues that may arise from exposure to harmful elements.
3. High-noise work environments
Occupational Safety and Health Administration (OSHA) laws and ISO 1999-1990 set strict standards for sound exposure limits for workers (a limit of 85dB for 8 hours and a general upper limit of 140dB) to prevent long-term damage to hearing. Robots can provide remote access to such an environment, and testing can be conducted without causing harm to the operators. The operation of these robots can also be automated to eliminate the need for human presence.
4. High Altitude work environment
Architectural and civil engineering advancements have led to the construction of increasingly and alarmingly tall structures. These structures are exposed to strong winds and natural elements, which may cause damage and weakening of the structure. Testing such structures at the upper regions which may have low atmospheric oxygen is not feasible for human operators and can cause pulmonary edemas and altitude sickness. NDT robots can prevent these issues and the risk of high-altitude fall-related accidents while maintaining thorough monitoring of the integrity of the structure.
5. A work environment with exceeding temperatures
Workplace regulations mandate that standard habitable temperatures should be maintained to prevent heat strokes among workers. However, if the workplace temperature exceeds 80°C, it is a matter of caution as it can cause excessive fatigue. At temperatures above 90°C, there are risks of heat strokes and organisations must proceed with extreme caution while engaging workers in those regions. Robots can be equipped with temperature-resistant suits operable in high-temperature regions. IP69K sensors and actuators are installed in such mechanisms to enable the heat and pressure resistance of the testing apparatus.
6. High radiation exposure environments
The Chernobyl nuclear reactor and the Fukushima nuclear reactor post accidents are some examples of heavy radiation zones that are inaccessible to humans without fatal radiation damage or long-term illnesses. These zones, however, needed to be accessed to curb damages and ensure safety. Robots such as the Joker were used in Chernobyl to replace humans for carrying out important clearing procedures, whereas Fukushima also employed the use of robots for inspection of the radiation-affected zones.
The acceptable radiation dosage for a human being as per the World Health Organization is only 50mSv a year. The increase in the use of nuclear energy and Nuclear Power Plants in modern-day technology demands that such heavy radiation zones be created. To ensure safety and stability, without risking human life, radiation-proof robots are employed with Non-destructive Testing apparatus to ensure the safety and smooth operation of facilities.
7. Testing environments in deep water:
Deepwater optical cables, petroleum industry rigs, ocean exploration, and nuclear power plants involve the presence of heavy machinery in deep water regions. The pressure in such regions is way above the permissible rate for professional divers. Human inspection and maintenance are difficult in such setups, necessitating advanced NDT techniques involving deep-sea robots. These robots also possess a higher range of motion than humans and can be used for multiple testing procedures.
Robotics in Non-Destructive Testing
Robots are beneficial for multiple NDT procedures like that of Radiography Testing. The highly penetrative X-rays and gamma rays pose multiple challenges that may hinder the accuracy of results. Robots are not limited by work hours or labor laws and can hence be used for round-the-clock NDT and analysis.
1. Advanced Materials:
The discovery and invention of new materials and composites create a need for new testing methodologies to ensure quality and integrity for manufacturing and service industries. Research and use of advanced sensors and embedded systems aid in the efficient analysis of such material so that advancement in its usage can be expedited and the benefits of these newer materials can be thoroughly utilised by newer technologies and structures.
2. Space Industry:
The Terahertz Technology is a new age non-destructive testing methodology used by NASA to test Space Shuttle tiles for corrosion. This Technique is no-contact and offers high-resolution results. This device operates between a frequency of 300GHz and 3THz. It can detect corrosion defects of a depth of approximately 0.13mm. Shuttle tiles are non-conductive and undergo harsh extremities ranging from the vacuum in space to marine landings and can be subject to Corrosion which is imperative to be detected and moderated. Terahertz is a heavily researched methodology that can help ensure space shuttle safety.
3. Oil and Gas Industries:
The Total Focusing Method (TFM) is an advanced technique of Phased Array Ultrasonic Testing that aids in detecting hydrogen damage in test materials. The testing apparatus is portable and provides high-resolution images, accurate readings, simplified characterisation of data, greater test zone coverage, slope visualisation, and reduction of the dead zone.
The Total Focusing Method (TFM) uses the induced ultrasonic energy and divides the test zone into pixels, extracting time of flight diffraction and amplitude data from each pixel. The amplitude data is summated for N(receivers) x N(emitters). This data is extracted for every pixel in the zone, providing rich resultant data.
4. Data Management:
The Big Data industry highly benefits from NDT as the advancements in the field lead to larger data sets and create the need for better data management. Ready access to old testing records aids in calculating data trends and can increase the sensitivity of the non-destructive testing mechanism.
5. Advanced Manufacturing:
Companies that utilise High-Value Manufacturing methodologies, with technical, skill, and knowledge-based processes to generate significant value and maintain novelty in innovativeness require NDT Methodologies in their main capabilities. Some of those abilities include:
I. Resource Efficiency
- Energy Generation Technologies
- Sustainability and through-life design and manufacturing
- Lightweight products, vehicle, and structure manufacturing
- Processing of biotechnical, biological, and synthetic biology
II. Manufacturing Systems
- Process capability in food, chemical, and pharmaceutical production
- Small-scale design and manufacturing
- Modeling of systems, simulation, and design
- Automation, mechanization, and interfaces
- PnP manufacturing
- Mechanical conversion for process optimization
- Design, manufacture, and inference of products
III. Materials Integration
- Smart, Hybrid, and composite materials
- Smart systems and embedded systems
- Advanced coating parameters
IV. Manufacturing Processes
- Flexible Manufacturing Systems
- Parallel Engineering
- Additive Manufacturing (SLA manufacturing or 3D printing)
- NNS manufacturing (Near Net Shape)
V. Business Models
- Fragmented chain management to support high-value manufacturing.
- Building new business models with flexible arrangements to create and support high-value manufacturing.
- Developing and retaining skills to support high-value manufacturing.
- Managing risk and resilience to support high-value manufacturing.
The future of NDT lies in advanced techniques using emerging technologies like AI, robotics, and digital twins. Future testing methods will focus on predictive maintenance, real-time monitoring, and sustainability to meet evolving industry demands. By integrating advanced NDT techniques, industries can achieve higher reliability, reduced downtime, and improved safety in applications.
Key Takeaways
- Advanced NDT techniques will drive predictive and real-time monitoring for enhanced decision-making.
- The future of NDT is centred on integrating AI, robotics, and sustainable practices.
- Emerging technologies will redefine testing efficiency, accuracy, and cost-effectiveness.
FAQs
1. How will advanced NDT techniques impact future testing?
A: Advanced NDT will enable more precise defect detection, real-time data analysis, and proactive maintenance strategies, reducing failures and operational costs.
2. What technologies will shape the future of NDT?
A: AI, digital twins, robotics, and IoT will play pivotal roles in transforming the capabilities and scope of NDT applications.
References
1. Eddyfi. (n.d.). Pushing the limits of advanced NDT to new heights. Retrieved from Eddyfi
2. KARTHIK SUNDARAM, PROGRAM MANAGER, IIOT. (n.d.). The Future of NDT. Retrieved from Frost & Sullivan
3. Nathaniel James. (n.d.). Illuminating the Future: Trends in the Non-Destructive Testing (NDT) Services Market. Retrieved from Verified Market Reports
4. NEXXIS. (n.d.). The Future Is Now: Everything You Need to Know About NDE 4.0. Retrieved from NEXXIS
5. VARMINE BIM. (n.d.). Unlocking the Potential of BIM in Non-Destructive Testing for Building Integrity. Retrieved from LinkedIn
