Identification of Defect in Friction Stir Welding Processed Material Using Microwave Non-Destructive Evaluation and Image Processing
Source abstract
Abstract
Abstract Manufacturers are looking intently for more rapid Friction Stir Welding (FSW), speeds in a manufacturing environment to improve quantity. The variable regions increase as welding speed increases, potentially leading to an increase in the number of defects. Consequently, it's essential to use an effective inspection method that uses non-destructive evaluation (NDE) to identify the surface defect origins. In the current proposal, a novel microwave-based non-destructive evaluation is utilized, employing an open-ended rectangular waveguide probe to detect defects in samples processed via FSW. The “Skin effect” approach is employed at microwave frequencies (8–12 GHz) for identifying potential external defects in welded samples. Further research indicated that the suggested interpolation image processing technique accurately identifies defects present within welded samples. This proposed microwave non-destructive evaluation model successfully predicted defects with a minimum deviation of 1mm.
Source: openaire · Quality: candidate unverified · Source record ↗
Research context
OpenAlex topics: Advanced Welding Techniques Analysis · Welding Techniques and Residual Stresses · Ultrasonics and Acoustic Wave Propagation
SciVX discovery tags are terminology-based. OpenAlex topics are source-provided classifications.
References (32)
Show source-provided references
1. Taheri, H., Kilpatrick, M., Norvalls, M., Harper, W.J., Koester, L.W., Bigelow, T., Bond, L.J.: Investigation of Nondestructive Testing Methods for Friction Stir Welding, (2019)10.3390/met9060624 ↗
2. Esmaily, M., Mortazavi, N., Osikowicz, W., Hindsefelt, H., Svensson, J.E., Halvarsson, M., Martin, J., Johansson, L.G.: Bobbin and conventional friction stir welding of Thick extruded AA6005-T6 profiles. Mater. Des. 108, 114–125 (2016). https://doi.org/10.1016/j.matdes.2016.06.08910.1016/j.matdes.2016.06.089 ↗
3. Akinlabi, E.T., Akinlabi, S.A.: Friction stir welding process: a green technology. (2012)
4. Kim, Y.G., Fujii, H., Tsumura, T., Komazaki, T., Nakata, K.: Three defect types in friction stir welding of aluminum die casting alloy. Mater. Sci. Eng. A. 415, 250–254 (2006). https://doi.org/10.1016/j.msea.2005.09.07210.1016/j.msea.2005.09.072 ↗
5. Rosado, L., Santos, T., Piedade, M., Ramos, P., Vilaça, P.: Advanced technique for non-destructive testing of friction stir welding of metals. Measurement. 43, 1021–1030 (2010). https://doi.org/10.1016/j.measurement.2010.02.00610.1016/j.measurement.2010.02.006 ↗
6. Saravanan, T., Lahiri, B.B., Arunmuthu, K., Bagavathiappan, S., Sekhar, A.S., Pillai, V.P.M., Philip, J., Rao, B.P.C., Jayakumar, T.: Non-destructive evaluation of friction stir welded joints by X-ray radiography and infrared thermography. Procedia Eng. 86, 469–475 (2014). https://doi.org/10.1016/j.proeng.2014.11.06010.1016/j.proeng.2014.11.060 ↗
7. Tunde Azeez, S., Madindwa Mashinini, P.: Radiography examination of friction stir welds of dissimilar aluminum alloys. Mater. Today Proc. 62, 3070–3075 https://doi.org/https://doi. (2022). https://doi.org/10.1016/j.matpr.2022.03.22510.1016/j.matpr.2022.03.225 ↗
8. Adamus, K., Lacki, P.: Assessment of aluminum FSW joints using ultrasonic testing. Arch. Metall. Mater. 62 (2017). https://doi.org/10.1515/amm-2017-035310.1515/amm-2017-0353 ↗
9. Inês Silva, M., Malitckii, E., Santos, T.G., Vilaça, P.: Review of conventional and advanced non-destructive testing techniques for detection and characterization of small-scale defects. Prog Mater. Sci. 138, 101155 (2023). https://doi.org/10.1016/j.pmatsci.2023.10115510.1016/j.pmatsci.2023.101155 ↗
10. Rabe, P., Reisgen, U., Schiebahn, A.: Non-destructive evaluation of the friction stir welding process, generalizing a deep neural defect detection network to identify internal weld defects across different aluminum alloys. Weld. World. 67, 1–12 (2023). https://doi.org/10.1007/s40194-022-01441-y10.1007/s40194-022-01441-y ↗
11. Hunt, J., Mazzeo, B., Sorensen, C., Hovanski, Y.: A generalized method for In-Process defect detection in friction stir welding. J. Manuf. Mater. Process. 6, 80 (2022). https://doi.org/10.3390/jmmp604008010.3390/jmmp6040080 ↗
12. Ragupathy, V.D., Bhat, R., Prasad, M.V.N.: An experimental study of discontinuities in friction stir welded joints through nondestructive testing. Mater. Eval. 75, 406–412 (2017)
13. Bhat, M.R., Ragupathy, V.D.: Characterisation of friction stir weld discontinuities by Non-destructive evaluation. Trans. Indian Inst. Met. 72, 2971–2979 (2019). https://doi.org/10.1007/s12666-019-01813-x10.1007/s12666-019-01813-x ↗
14. Wahab, M.A., Dewan, M.W., Huggett, D.J., Okeil, A.M., Liao, T.W., Nunes, A.C.: Challenges in the detection of weld-defects in friction-stir-welding (FSW). Adv. Mater. Process. Technol. 5, 258–278 (2019). https://doi.org/10.1080/2374068X.2019.157571310.1080/2374068X.2019.1575713 ↗
15. Singh, R.: Weld Cracking in Ferrous Alloys. Woodhead Publishing (2008)10.1533/9781845695453 ↗
16. Sanaei, N., Fatemi, A.: Defects in additive manufactured metals and their effect on fatigue performance: A state-of-the-art review. Prog Mater. Sci. 117, 100724 (2021). https://doi.org/10.1016/j.pmatsci.2020.10072410.1016/j.pmatsci.2020.100724 ↗
17. Rahman, M.S., ur, Gaya, S.M., Abou-Khousa, M.A.: Non-destructive Testing and Evaluation of Surface-Breaking Cracks using Microwave Planar Resonator Probe. In: 2022 IEEE Microwaves, Antennas, and Propagation Conference (MAPCON). pp. 552–556 (2022)10.1109/MAPCON56011.2022.10046702 ↗
18. Qiu, G., Tian, S., Yuan, Q.: Research of crack defect detection in metal pipes based on microwave antenna array. Wirel. Commun. Mob. Comput. 2022 (2022). https://doi.org/10.1155/2022/966309110.1155/2022/9663091 ↗
19. Qian, B., Mou, L., Wu, L., Xiao, Z., Hu, T., Jiang, J.: A Direction-Sensitive Microwave Sensor for Metal Crack Detection, (2022)10.3390/app12189045 ↗
20. Abou-Khousa, M., Rahman, M., Donnell, K., Qaseer, M.: Detection of surface cracks in metals using microwave and Millimeter-Wave nondestructive testing Techniques—A review. IEEE Trans. Instrum. Meas. PP. 1 (2023). https://doi.org/10.1109/TIM.2023.323803610.1109/TIM.2023.3238036 ↗
21. Salski, B., Gwarek, W., Korpas, P.: Electromagnetic inspection of Carbon-Fiber- reinforced polymer composites with coupled spiral inductors. IEEE Trans. Microw. Theory Tech. 62, 1535–1544 (2014)10.1109/TMTT.2014.2325537 ↗
22. Sayar, M., Seo, D., Ogawa, K.: Non-destructive microwave detection of layer thickness in degraded thermal barrier coatings using K- and W-band frequency range. NDT E Int. 42, 398–403 (2009). https://doi.org/10.1016/j.ndteint.2009.01.00310.1016/j.ndteint.2009.01.003 ↗
23. Akbar, M.F., Sloan, R., Duff, C., Wielgat, M., Knowles, J.: Microwave nondestructive evaluation of thermal barrier coated turbine blades using correlation analysis. (2016)
24. Anbalagan, A., Ramalingam, V.S., Sundarsingh, E.F., Subbaraj, S.: A novel microwave-based non-destructive testing system for detection of sub-surface defects in natural flax fiber reinforced composite material. Proc. Inst. Mech. Eng. Part. L J. Mater. Des. Appl. 14644207231195996 (2023). https://doi.org/10.1177/1464420723119599610.1177/14644207231195996 ↗
25. Arbeláez, P., Maire, M., Fowlkes, C., Malik, J.: Contour detection and hierarchical image segmentation. IEEE Trans. Pattern Anal. Mach. Intell. 33, 898–916 (2011). https://doi.org/10.1109/TPAMI.2010.16110.1109/TPAMI.2010.161 ↗
26. Liu, Y., Liu, H., Chen, Z.: Post-fire mechanical properties of aluminum alloy 6082-T6. Constr. Build. Mater. 196, 256–266 (2019). https://doi.org/https://doi.https://doi.org/10.1016/j.conbuildmat.2018.10.23710.1016/j.conbuildmat.2018.10.237 ↗
27. Egels, G., Mujica Roncery, L., Fussik, R., Theisen, W., Weber, S.: Impact of chemical inhomogeneities on local material properties and hydrogen environment embrittlement in AISI 304L steels. Int. J. Hydrogen Energy. 43, 5206–5216 (2018). https://doi.org/10.1016/j.ijhydene.2018.01.06210.1016/j.ijhydene.2018.01.062 ↗
28. Benson, M.: Fields, Waves and Transmission Lines. Springer Netherlands (2012)
29. Sutthaweekul, R., Tian, G., Wang, Z., Ciampa, F.: Microwave open-ended waveguide for detection and characterisation of FBHs in coated GFRP pipes. Compos. Struct. 225, 111080 (2019)10.1016/j.compstruct.2019.111080 ↗
30. Li, Y., Qi, F., Wan, Y.: Improvements On Bicubic Image Interpolation. In: 2019 IEEE 4th Advanced Information Technology, Electronic and Automation Control Conference (IAEAC). pp. 1316–1320 (2019)10.1109/IAEAC47372.2019.8997600 ↗
31. Sun, J., Wang, W., Yue, Q., Ma, C., Zhang, J., Zhao, X., Song, Z.: Review on microwave–metal discharges and their applications in energy and industrial processes. Appl. Energy. 175, 141–157 (2016). https://doi.org/10.1016/j.apenergy.2016.04.09110.1016/j.apenergy.2016.04.091 ↗
32. Reshi, H.A., Pillai, S., Singh, A.P., Wani, A.A., Dhawan, S.K., Shelke, V.: Ku-Band Radiation Shielding Response of La0.7Sr0.3MnO3 Thin Film BT - Advanced Functional Materials for Sustainable Environments. Presented at the (2024)10.1007/978-3-031-62620-3_25 ↗