Table of Content
- What is NDE 4.0
- Challenges and Possibilities
- Challenges Faced in the Implementation of NDE 4.0 are as follows
- Advantages and Disadvantages
- Difference Between NDT and NDE 4.0
- Technology Used in NDE 4.0
- Conclusion
What is NDE 4.0?
Technological advancement in the history of mankind has been divided into ages, to better understand the correlation of the growth of mankind, to the social and political history and availability of resources. The discovery of tools was the genesis of technological growth, occurring around 200000 BC. The use and discovery of metallurgy did not ensue until 3600 BC.
This industrial revolution marked the use of gold, bronze, iron, alloys, chemistry, and steel. This revolution could be considered an industrial revolution of materials, or the first industrial revolution. The growth of NDT Technology has undergone exponential growth since then, with the energy-providing system shifting from human and animal-based effort to the use of naturally available resources like coal, steam, etc.
This second industrial revolution caught on like wildfire and led to the worldwide use of technology like steam engines, trains, steamboats, etc. This revolution was considered a revolution of energy production and helped connect the world with better transport and resource exchange, hence paving the path for greater access to labor, technology, and resources.
As the demand for more resources, facilities, and luxuries increased, the load on manufacturing units and production capabilities escalated. This led to the upgradation of the manufacturing unit to produce multiple units of the same material using different methodologies and changed labour management drastically. The introduction of the Ford Model T automobile revolutionized the world of manufacturing as the concept of mass production was introduced to the world, in the form of the first automotive assembly line.
The third industrial revolution of mass production was significant in creating many products and facilities at progressively lower rates and in shorter periods. This third industrial revolution was called the revolution of mass production. The twentieth and twenty-first centuries marked the growth of computers. This fourth industrial revolution is being connotated as industry 4.0 and signifies the amalgamation of existing technologies with more advanced systems like Artificial Intelligence, big data processing, blockchain, internet of things, digital twins, digital thread, semantic interoperability, industry 4.0 data processing, and the cloud.
Non-destructive Evaluation 4.0 embodies the concept of Industry 4.0, as it adopts automation to process some of the most vital, often precarious, cumbersome, and human resource-depleting requirements, to make it completely streamlined and digital. The use of sensors, robots, drones, and the cloud reduces the need for constant human involvement in quality, safety, and structural integrity inspections and enables more efficient work systems, devoid of any waste or redundancies.
Challenges and Possibilities
NDE 4.0 encompasses all the salient features of Industry 4.0 and is used to analyze the entire process flow of a product from its conception as a raw material, to the machining processes, inspection processes, categorization, and induction into the markets, along with examination during its operation under load.
NDE 4.0 includes the creation of three-dimensional volumes, handling of large data sets and files, big data management, in-operational analysis of structures to ensure lack of defects and deformities, remote access to knowledge to tackle obstructions in process, planning of non-destructive evaluation based on modeling and meticulous evaluation of parts as they are produced. As per the industry 4.0 demand for the ‘smart factory’, NDE 4.0 is warranted to consolidate the concepts and apparatus of non-destructive testing into industrial systems with automated mechanisms of inspection and digital or artificial intelligence-based inference of data obtained.
Probability-based models such as Probability of Detection (PoD) and Receiver Operating Characteristic (ROC) curves, which are used in Non-destructive Evaluation inspections are required to be introduced to production and inspection processes, to enable better asset integrity management. NDE 4.0 also necessitates continuous monitoring of processes and machinery while in operation and the digital integration, transfer, communication, assessment, and handling of the data obtained during automated inspections using Big Data concepts.
Challenges Faced in the Implementation of NDE 4.0
1. Transition of Skill Sets:
Existing Non-destructive Testing apparatus and methodologies require completely different categories of skills, which, after the implementation of NDE 4.0, will be rendered irrelevant. Skills like the knowledge of materials, temperature, behaviour, and installment of apparatus will be replaced by knowledge of information technologies and communication systems. Operators, administration, and personnel will have to accept the rapid redundancy of the knowledge they acquire and learn to constantly keep updating their skill set as per the requirements of the process and industry demands.
2. Adaptation to existing systems:
Profit and economic viability are of utmost importance to every industry, and the large-scale implementation of industry 4.0 and NDE 4.0 can be a drastic change that involves the expenditure of human resources, capital, and hierarchy. Industry 4.0 and NDE 4.0 call for the growth of a new style of leadership and administration, led by flexible, involved, and competent leaders. These people should be the pioneers of flexible thinking, acquisition of knowledge, and implementation of higher technology, without getting caught in the rut of penny-pinching budgeting and short-sightedness.
3. Lack of Awareness
The concepts of NDT have yet to be adopted by a lot of organizations, as the concept of higher initial investment for long-term reduction of resources and capital losses has often been met with trepidation. NDE 4.0 and NDT Technology can often be expensive, hence many organizations are reluctant to adopt these systems on the pretext of them being unviable and nugatory.
Advantages and Disadvantages of NDE 4.0
The advantages of NDE 4.0:
- Improvement of existing non-destructive testing techniques.
- The rapid advancement of NDT apparatus and machinery.
- Improved process control, hence increasing the efficiency of processes.
- Adoption of Kaizen (continuous improvement) through the mining of data in processes.
- Improved quality checks for components produced through additive manufacturing.
- Elimination or reduction of human error in testing processes
- Ensuring the safety of operators and personnel by remote access to testing in hazardous areas.
- Utilization of drones and robots to carry out cumbersome testing procedures, hence relocating human resource power to productive tasks.
The disadvantages of NDE 4.0:
- Revision of existing standards
- Functionality of digital connectivity
- Change in management processes.
- Digital security risks
Difference Between NDT and NDE 4.0
NDT can be divided into four phases of its evolution, wherein NDT is a collective term used to describe the first three phases, whereas NDE 4.0 is the fourth phase and is significant as it marks the integration and transition to the fourth industrial revolution. The first phase of non-destructive testing was concurrent with the First Industrial Revolution, where the increase in the use of steam engines created a demand for the safety testing of facilities, vehicles, and machines. Basic tools and Visual Testing were used during this phase to ensure the usability of the test subjects.
The second phase of NDT involved the use of electricity and the increase in the use of electronic devices. Concurrent with the Second Industrial Revolution, the industries graduated from the use of basic tools and visual methods of testing to using technology ultrasonic waves, x-rays, gamma rays, Magnetic Particle Inspection, dye penetrant inspection, and liquid penetrant inspection. These methodologies ventured into waves beyond the visible range in the electromagnetic spectrum and the use of additional materials applicable to the surface of test subjects to detect flaws and cracks.
The third phase of Non-destructive Testing focused on improving data handling and enabled the use of sensors, transducers, data storage, imaging software, and programming. The usage of processes like Ultrasonic Testing, phased array ultrasonic testing, computed tomography, eddy current inspection, and Radiographic Testing gained momentum.
The current phase is also known as the Future of Non-destructive Testing, or NDE 4.0. NDE 4.0 amalgamates the features, technologies, and data management of all the versions of non-destructive. NDE 4.0 enables remote access, which protects the operators from the hazards of the former, i.e., NDT 3.0 methodologies like X-ray testing, etc. Improved communication and data management also plays a major role in the advantages of NDE 4.0.
Human involvement and inference are vital in the former trends in non-destructive testing, however, in NDE 4.0, machine learning, artificial intelligence, and programming have reduced the weightage on that factor. The inspection performance and probability of errors have been minimized, hence opening the avenues for higher-quality products and processes. The salient features of the individual stages of progress of Non-destructive Testing remain unchanged, however, and advancement in any individual methodology does not upgrade it to the next stage of non-destructive testing unless it adopts the features of that specific stage of technology.
Technology Used in NDE 4.0
The technologies involved in the implementation of NDE 4.0 are as follows:
1. Artificial Intelligence / Machine Learning / Deep Learning
These NDE methods train computers to process data like a human brain. Deep learning and machine learning the vital technology that enables machinery, drones, and robots to operate independently and make functional decisions in a process. Machine Learning can be used to detect and analyze patterns and repeatability in images, text, sound, and data to create inferences and chart trends.
2. Big/Smart Data Processing and Visualisation
Data processing and visualization consists of four major stages, which involve, the collection of data, storage of data, data analysis, and creation of inferences. The goal of big data is to create deductions by crunching large datasets. This is done by making the data concise or summarising it, as appropriate. The concept of visualization of data uses graphical and visual tools like charts and tables to produce these inferences in a simplified manner.
3. Cloud Computing
Cloud computing provides users with to option to access data, software, and other computing resources online. Cloud computing is available for a variety of applications and can be accessed as a private cloud, public cloud, hybrid cloud, and multi-clouds.
4. Augmented / Virtual / Mixed Reality
Augmented Reality provides visual access to physical words with overlaying digital elements. Virtual Reality creates a simulated digital environment that the user is immersed in, whereas Mixed reality (MR) provides the same visual access to the physical world as AR, however, the digital elements in MR can interact with real-world elements.
5. Blockchain
Blockchain is like a dispersed digital ledger and has picked great momentum in the tech world. There are four types of blockchains, namely private blockchain, public blockchain, consortium blockchains, and hybrid blockchains. Blockchain records information in a secure manner to avoid tampering at all costs.
6. Quantum Computers
A quantum computer is a system that utilizes the phenomena of quantum mechanics. The basic storage symbol or unit of quantum computing is called a qubit, into which data in the state of quantum information is recorded. A quantum computer runs quantum algorithms in multiple dimensions using qubits. In classical two-state computers, a qubit would equate to the concept of bits. The processing power of the quantum computer is directly proportional to the number of qubits in the system. The performance of a quantum computer is exceedingly better than supercomputers and can provide astoundingly elite performance.
7. Enhanced Robotics/Drones
A drone is a remote-controlled flying robot that can be used to perform pre-programmed tasks. Embedded systems are used to enable these enhanced robots and drones to perform independently. The usage of drones reduces human involvement in hazardous processes and NDT Testing procedures and can be used to access uninhabitable and inaccessible test zones.
8. Revision-Safe Data Formats and Storage
This refers to the category of digital storage methodologies that ensure the safe retention of information, security addresses, and documents.
9. Digital Twin
This technology involves creating a virtual counterpart or clone of a real-world object, system, or process that can be utilized to create simulations, analysis, maintenance studies, and monitoring. Digital twins are generally of three types, namely, product, production, and performance.
10. Industrial Internet of Things
Unlike the regular concept of the internet of things wherein the consideration involves the physical interconnection between physical devices, the Industrial Internet of Things includes industrial components and elements like sensors, instruments, medical devices, etc. with the systems of industrial applications.
11. Data Security/Sovereignty
Data that has been stored and converted securely into binary information is dependent on the laws of the country it has been secured and stored.
12. Semantic Interoperability
This is the concept of ensuring that computer systems retain the format and meaning of data when it is exchanged between systems without computational errors.
13. Additive Manufacturing
Additive manufacturing includes processes like 3D printing, or Stereolithography, wherein, a product is fabricated layer by layer by focusing a laser on the surface of a photosensitive liquid. Most popular manufacturing methods like Lathe, Milling, Drilling, etc are subtractive in nature and have multiple design and process limitations.
14. Reliability
Reliability is the ability of a product, process, or system to operate at its intended load-carrying state, in a particular environment without undergoing failure.
15. Predictive and Prescriptive Maintenance
Prescriptive maintenance is an asset management strategy that accounts for past trends in performance and current performance data and makes inferences for the repairs or maintenance the system or process requires. Whereas predictive performance only considers past trends in data to produce such information.
16. Lifing/Probabilistic Analysis
Lifing is a quantitative understanding of the number of times a component or machinery can be utilized until it is inoperative due to failure. Probabilistic analysis is used to analyze such quantities using probability.
17. Trending / Feedback Loops
Feedback loops come in two forms, namely positive (reinforcing) feedback and negative (balancing) feedback. These suggestions are consistently used for the continuous improvement of a product, process, or mechanism. This process is called a feedback loop.
Conclusion
- NDE 4.0 is still in its nascent stages, and like every new technological field or concept, it has been met with skepticism.The main concern is that it would result in the redundancy of manpower.
- The inception of NDE 4.0 opens avenues for technological advancement that had once been limited by the range of motions, hazardous environments, and unbearable workloads.
- Industry 4.0 will also make Non-destructive Evaluation Equipment affordable and accessible to various organizations, improving the quality and integrity of various functions at a global scale, which will in turn encourage the transition to NDE 4.0. This will cause a revolution in the way the world views and accesses technology, products, and resources.
References
1. Falcon Inspection & Service
2. Meyendorf, Norbert
3. ECNDT
