NDT, Volume 2, Issue 3 (September 2024) – 13 articles

To optimally preserve and manage our civil structures, we need to have accurate information about their (1) geometry and dimensions, (2) boundary conditions, (3) material properties, and (4) structural conditions. The objective of this article is to show how imaging and image fusion using non-destructive testing (NDT) measurements can support structural engineers in performing accurate structural evaluations. The proposed methodology involves imaging using synthetic aperture focusing technique (SAFT)-based image reconstruction from ground penetrating radar (GPR) as well as ultrasonic echo array (UEA) measurements taken on multiple surfaces of a structural member. The created images can be combined using image fusion to produce a digital cross-section of the member. The feasibility of this approach is demonstrated using a case study of a prestressed concrete bridge that required a bridge load rating (BLR) but where no as-built plans were available. Imaging and image fusion enabled the creation of a detailed cross-section, allowing for confirmation of the number and location of prestressing strands and the location and size of internal voids. This information allowed the structural engineer of record (SER) to perform a traditional bridge load rating (BLR), ultimately avoiding load restrictions being imposed on the bridge. The proposed methodology not only provides useful information for structural evaluations, but also represents a basis upon which the digitalization of our infrastructure can be achieved. Full article

This research investigates the characterization of bituminous mixes utilizing microwave imaging and non-destructive testing. We studied the electromagnetic characteristics of various samples, including bituminous concrete (BC) and open-grade friction course (OGFC) samples. A novel ring filter with log-periodic feedlines, designed on the RT/Duroid 5880 substrate, was utilized within the frequency range of 0.3–0.7 GHz. The samples were assessed using average attenuation and group delay measures, which detailed clear electromagnetic characteristics. The samples’ flow value and specific gravity were correlated to these parameters. The calculated flow value and specific gravity (using the filter) and measured flow value and specific gravity (using the conventional method) coincided well. The filter could predict the parameters of the samples with a high accuracy of roughly 99.8% for the flow value and specific gravity, whereas the OGFC sample displayed an accuracy of 99.7%, correspondingly, as shown in high R² values. This demonstrates that the filter can precisely measure the parameters required for studying the interaction between the binder and aggregate in bituminous mixes without being invasive. The findings indicate a significant disparity between OGFC and BC samples in their responses to electromagnetic fields and their characteristics. This demonstrates the high sensitivity and significant value of microwave techniques in the study of bitumen and the construction of roadways. Full article

The increasing complexity of material systems requires an extension of conventional non-destructive evaluation methods such as ultrasonic testing. Many publications have worked on extending simulation models to cover novel aspects of ultrasonic transducers, but they do not cover all components of the system. This paper presents a physically motivated, modular model that describes the complete signal flow with the aim of providing a platform for optimizing ultrasonic testing systems from individual components to the whole system level. For this purpose, the ultrasonic testing system is divided into modules, which are described by models. The modules are each parameterized by physical parameters, characteristics of real components as provided by datasheets, or by measurements. In order to validate the model, its performance is presented for three different configurations of a real test system, considering both classical sinusoidal excitation and a chirp signal. The paper demonstrates the modularity of the model, which can be adapted to the different configurations by simply adapting the modified component, thus drastically reducing the complexity of modeling a complex ultrasonic system compared to State-of-the-Art models. Based on this work, ultrasonic inspection systems can be optimized for complex applications, such as operation with coded excitation, which is a major challenge for the system components. Full article

Intending to safeguard architectural heritage, the assessment of the health of timber structures is crucial, though challenging, due to the organic nature of wood and to the uncertainties of its preservation state. To this end, useful support is provided by the ICOMOS guidelines, which provide conservation strategies based on thorough diagnosis and safety evaluations. In this context, the study summarized in this paper focuses on the medieval Tower of Montorio, which suffered considerable damage due to the strong earthquake that occurred in those area in September 2003. Its subsequent process of rehabilitation and restoration involved a widespread experimental campaign and the substitution of some timber beams. This circumstance has offered a rare opportunity to study these ancient elements in detail, although they are limited in number. Six beams made of oak and removed from an intermediate floor of the tower were evaluated through a comprehensive approach that included both non-destructive tests (NDT) and destructive tests (DT). Particularly, they were subjected to visual inspections, ultrasonic, sclerometric, and resistographic methods, and destructive four-point bending tests. Overall, the study presented here provides a useful qualitative comparison between them. Results highlighted that relying only on NDT might lead to an overestimation of mechanical properties and that combining NDT with DT is crucial for a more accurate assessment. Therefore, the need to deepen the research on correlations between NDT and DT to obtain reliable values of mechanical properties while respecting the conservation aim was confirmed. Full article

Computed tomography (CT) is a widely utilised imaging technique in both clinical and industrial applications. CT scan results, presented as a volume revealing linear attenuation coefficients, are intricately influenced by scan parameters and the sample’s geometry and material composition. Accurately mapping these coefficients to specific materials is a complex task. Traditionally, material decomposition in CT relied on classical algorithms using handcrafted features based on X-ray physics. However, there is a rising trend towards data-driven approaches, particularly deep learning, which offer promising improvements in accuracy and efficiency. This survey explores the transition from classical to data-driven approaches in material-sensitive CT, examining a comprehensive corpus of literature identified through a detailed and reproducible search using Scopus. Our analysis addresses several key research questions: the origin and generation of training datasets, the models and architectures employed, the extent to which deep learning methods reduce the need for domain-specific expertise, and the hardware requirements for training these models. We explore the implications of these findings on the integration of deep learning into CT practices and the potential reduction in the necessity for extensive domain knowledge. In conclusion, this survey highlights a significant shift towards deep learning in material-resolving CT and discusses the challenges and opportunities this presents. The transition suggests a future where data-driven approaches may dominate, offering enhanced precision and robustness in material-resolving CT while potentially transforming the role of domain experts in the field. Full article

This study addresses the critical issue of cardiovascular diseases (CVDs) as the leading cause of death globally, emphasizing the importance of stent delivery catheter manufacturing. Traditional manufacturing processes, reliant on destructive end-of-batch sampling, present significant financial and quality challenges. This research addresses this challenge by proposing a novel approach: a closed-loop cyber-physical production system (CPPS) employing non-destructive process analytical technology (PAT). Through a mixed-method approach combining a comprehensive literature review and the development of a CPPS prototype, the study demonstrates the potential for real-time quality control, reduced production costs, and increased manufacturing efficiency. Initial findings showcase the system’s effectiveness in streamlining production, enhancing stability, and minimizing defects, translating to substantial financial savings and improved product quality. This work extends the author’s previous research by comparing the validated system’s performance to that of pre-implementation manual workflows and inspections, highlighting tangible and intangible improvements brought by the new system. This paves the way for advanced control strategies to revolutionize medical device manufacturing. Furthermore, the study proposes a generalized CPPS framework applicable across diverse regulated environments, ensuring optimal processing conditions and adherence to stringent regulatory standards. The research concludes with the successful demonstration of innovative approaches and technologies, leading to improved product quality, patient safety, and operational efficiency in the medical device industry. Full article

The research related to subsea inspection, and the prediction of corrosion is a challenging task, and the progress in this area is continuously generating exciting new developments that may be used in subsea inspection. Wall thickness monitoring is an important tool to control and predict corrosion, such as on platforms for the infrastructure of floating offshore wind power production. This study shows the results obtained in marine environments. For this experiment, a steel plate equipped with ultrasound transducers was placed in seawater to corrode naturally. The sensor test setup consisted of 15 ultrasound transducers and 1 temperature sensor, which were installed in the cassette. The data acquisition system was based on a standard industrial computer with software written in Python and MATLAB. The ultrasound signals were collected at regular intervals and processed to calculate the instantaneous wall thickness. The progress of corrosion was evaluated by trend plots of wall thickness versus time, and the change in shape of the ultrasonic back wall reflection waveform measured by each sensor. Full article

Starting from January 2023, Permanent Staff Personnel and Associated Personnel of INFN-LNF (Istituto Nazionale di Fisica Nucleare—Laboratori Nazionali di Frascati) have founded, and are setting up, the local Astrophysics and Cosmology Team (ACT). The INFN-LNF ACT joined the initial development phases of one of the forthcoming (early 2030) next-generation cosmology space-borne probes, with particular emphasis on (1) thermal balance tests (and correlation to models) of the electronics of interest; (2) (non)destructive irradiation tests of the electronics of interest and X-ray circuitry diagnostics on a specifically dedicated and instrumented optical bench; and (3) joining the simulation-related, and data analysis-related, activities, at both the cosmological and instrumental levels. The INFN-LNF ACT has constituted an Integrated Test Facility (ITF), which is being instrumented in a dedicated space and will also make use of the pre-existing INFN-LNF infrastructures. In the following, as a first contribution, mainly related to what was completed in late 2023 and early 2024, the activities of the commissioning and setup of the so-called ‘pocket’ cryostat are described, linking them to the envisaged thermal balance tests (and correlation to the models) of the electronics of interest. While mainly devoted to cosmology-oriented tasks, the INFN-LNF ACT ‘pocket’ cryostat will, in principle, be available to the wider community for other dedicated activities. Full article

Additive Manufacturing (AM) of parts used in nuclear power plants can solve many issues like those related to obsolescence. Of the gap limiting the use of AM parts in nuclear is the need of reliable non-destructive inspection capable to meet the qualification requirements. Recently, efforts in this direction have been made worldwide within several research projects, like the EU Horizon 2020 NUCOBAM. In the framework of NUCOBAM, this article presents the activity related to the inspection of 316-L AM nuclear parts produced by L-PBF and inspected via advanced ultrasonic (UT) methods, like MultiPoint Focusing (MPF) and Total Focusing Method (TFM). Multiple UT array probes are used, linear, matrix and annular. Emphasis is dedicated to the inspection of classified valve bodies produced with known internal seeding flaws. The analysis of the results shows the effect of AM induced anisotropy on the propagation of the ultrasonic wave characteristics, the sound velocity increased with 3% when the sound beam deviated 15° against the perpendicular axis. The TFM method contributed significantly regarding defect detection, Signal to Noise Ratios (SNR) increased with at least 9 dB compared to the Multi-Point Focusing method. Smaller errors were noticed when examination frequency was increased and TFM was applied. The combination of an annular array with TFM and mechanical scanning demonstrated to be the best approach. Full article

The incorporation of natural fibers into concrete has recently emerged as a popular approach in the field of construction materials due to its sustainability and environmental friendliness. In comparison to artificial fibers, natural fibers are more cost-effective and widely available globally. Among the various natural fibers, coconut fiber (CF) stands out for its unique set of advantages. This study aims to investigate the mechanical properties and durability of coconut-fiber-reinforced self-healing concrete (CFR-SHC) in the context of corrosion resistance. Additionally, Bacillus subtilis bacteria (10% by mass) was incorporated into the CFR-SHC. The impact of ±50 mm long CF with varying contents of 0.25%, 0.5%, and 0.75% by mass was examined. Specimens were subjected to corrosion acceleration for 48, 96, and 168 h. Non-destructive testing (NDT) methods of Electrical Resistivity (ER) and Impact Echo (IE) were conducted to test the corrosion resistance. The experimental results demonstrate that CFR-SHC increased the compressive strength by 6% and the flexural strength by 40%. CFR-SHC also exhibits excellent resistance to corrosion, characterized by low inrush current, high ER value, and high IE frequency. The most favorable overall outcomes were observed for the CFR-SHC sample containing 0.5% of the cement mass. Full article

Geophysics is a fundamental tool to detect buried structures of archaeological interest through non-destructive techniques. The Messapian city walls in Ugento (Puglia, southern Italy) are of great archaeological importance, and some sections are still visible. In order to locate a stretch of the city walls, geophysical prospections were performed using the low-frequency electromagnetic method and ground-penetrating radar. The surveys were carried out in a peripheral area of Ugento, near a visible section of the city walls. The analysis and interpretation of the measured data revealed clear anomalies that could be ascribed to the city walls that aligned with an adjacent section of the visible walls. Archaeological excavation campaigns found a part of the walls and some important elements, as identified by the geophysical data interpretation. Full article

The work conducted in this study was designed to establish achievable testing tolerances for non-destructive pavement density measurements using Density Profiling Systems (DPSs). Nine and six sensors were used to determine the precision of repeatability and reproducibility in the laboratory and the field, respectively. A minimum of six sensors (considered in this study as independent laboratories) were needed to comply with the minimum number of participants required in the current ASTM standard practice (ASTM E691). The methodology included the development of laboratory precision evaluation with a total of nine sensors and two different mixtures (9.5 mm fine-graded mix, 19.0 mm coarse-graded mix) compacted at four density levels (97%, 94%, 91%, and 88% of G_mm). For the field portion of this study, pavement sections built at the National Center for Asphalt Technology (NCAT) Test Track in 2021 served as experimental variables. These sections were built with fine-graded asphalt mixtures and open-graded mixes as wearing courses. Additionally, the pavement sections included three underlying materials: new asphalt (binder layer), milled asphalt surface, and granular base, with thicknesses ranging from 3.8 to 13.9 cm. Density profile testing was conducted at two locations: within the mat (center of the lane) and along the joint. Computed precision statements regarding dielectric values within and between laboratories were about double for field results compared to laboratory results. However, when converted to density, the statements were significantly below the reported statements for Bulk Specific Gravity and Vacuum Sealing in the laboratory and Nuclear and Electromagnetic density gauges in the field. Full article

Concrete is the second most common material demanded over the world. Recently, a trending issue is the vast tracking in constructing infrastructure to ensure traffic movement and life quality. Concrete types such as self and rolled compacted concrete offer magical solutions ensuring vast infrastructure and life quality. However, these structures must be assessed using non-destructive testing methods to observe the difference between the concrete types. Several studies have used recycled waste, specifically the crumb rubber extracted from old tires, as a potential replacement for natural aggregate in concrete manufacturing. However, limited research has been devoted to nondestructive testing of produced concrete to further evaluate existing concrete elements containing crumb rubber. This study investigates the self and rolled compacted concrete in comparison with normal ones, in addition to using chopped rubber as recycled materials. This study examines the concrete manufactured destructively by evaluating its compressive, tensile, and flexural strength, in addition to impact resistance, and correlates those results with the non-destructive such as Schmit hammer and Ultrasonic Pulse (UPV) for extended utilization of the concrete produced and data publication. The results showed unique performance and a high potential for data contribution to the extensive utilization of self-compacted rubberized concrete and rolled compacted concrete. Full article