MACHINE FAULT DIAGNOSTICS

NON DESTRUCTIVE TESTING METHODS

BY
KABILAN.K
 Acoustic Emission

 The location of crack can be found by the location corresponding

to the sensor received the signal
 The Propagation of crack can be found as the waves grow in
number due to crack propagation.
 Weld monitoring, Bucket truck integrity check, Bridges, Aerospace
structures
 Early detection of crack
 Less costly
Location techniques for sensors

Linear Zonal location

Multi channel Point location

Principle

 When, a structure or material is subjected to an external stimulus

localized sources triggers the release of energy as stress waves and
propagates through surface.
 The external stimulus may be change in pressure, stress or
force/moments.
 The intensity of the waves depends on the size shape and the
distance from the crack.
 Acoustic energy – Transient elastic energy waves by the rapid
release of energy.
Methodology

 The transducers are placed on the

surface of the structure and are
connected to the data acquisition
module.
 When the force is applied the
emission is recorded and the same
is plotted for the variation in the
emission.
 The noises from environment to be
eliminated for better results.
Methodology
Case Study

Study and Application of Acoustic Emission Testing in Fault Diagnosis of

Low-Speed Heavy-Duty Gears

Lixin Gao 1, Fenlou Zai 1, Shanbin Su 1, Huaqing Wang 2,*, Peng Chen 3
and Limei Liu 4
Acoustic emission method for Gears
 SHEAROGRAPHY

• It is a full-field interferometric technique

• used for surface displacement derivatives
• Resilient to environmental disturbances.
• Suitable interferometric technique outside of lab.
• Directly measure strain with high sensitivity
 PRINCIPLE
When a two light waves of same
frequency combine they form either destructive
or constructive interference the intensity based
on the phase difference between them.

If they both are in out phase the

destructive interference is formed else if, in
phase then constructive interference is formed.
METHODOLOGY

• The laser output is illuminates the region

of surface being tested
• The scattered light forms laser speckle
pattern and shearing device splits the
image into 2 identical, but displaced
images.
• The 2 images forms a interferometric
speckle pattern is captured by CCD
camera.
CASE STUDY

Digital Shearography for NDT: Phase Measurement Technique and Recent

Dev
Qihan Zhao 1, Xizuo Dan 1,2, Fangyuan Sun 1, Yonghong Wang 1, Sijin Wu 3
and Lianxiang Yang 2.

Shearography for composite material lamina shear

 REMOTE FIELD TESTING

• Electromagnetic testing method.

• Can access both ID and OD.
• Sensitive to wall thickness.
• Can be used on ferromagnetic materials

• Requires skilled & experienced technicians

• High cost of equipments
PRINCIPLE

• The basic principle used is that the electromagnetic fields properties are affected by the
medium they are passing through.
• The probe for the electromagnetic detectors have made to flexible type with exciter and
detector coils so as to reach the remote locations of the specimen.
• The probes are made in the specific requirement of each applications.
 METHODOLOGY

• The Exciter coil is energized with AC sine

wave at 1Hz to 1kHz.
• The electromagnetic waves pass through the
tube section and passed to the detector coil
once again through the tube thickness.
• The optimal distance between the both coils
is 3 times of tube diameter • The difference between the signal
received from that of passed signal
gives the defect information.
• The field inside the tube to be
reduced to near zero for accuracy
CASE STUDY

Increased Use of Remote Field Technology for In-Line Inspection of Pipelines

Proves the Value of the Technology for this application
David RUSSELL and Vincent SHEN Russell N.D.E. Systems Inc.

RFT for Inspection of heat exchanger and boiler pipelines