An in-line inspection (ILI) tool 20 for use inspecting pipelines includes a plurality of collapsible guide centralizers 100 configured and sized to correspond to the inside diameter of the pipeline being inspected. The guide centralizes 100 include wheels 102 roll along the inside wall of the pipeline being inspected to maintain the guide centralizers “centered” within the pipeline. A collapsible exciter unit centralizer 200 is positioned between collapsible guide centralizers 100 to “center” the exciter unit centralizer relative to the interior of the pipeline. The exciter unit centralizer 200 generates signals in the form of an alternating magnetic field that travel along the wall of the pipeline which in turn generates eddy current signals. The eddy current signals undergo a change if a discontinuity in the pipeline is encountered by the inspection tool 20, which signal change or deviation is detected by a collapsible detector unit centralizer 300 positioned between the collapsible guide centralizers 100.

Eddy current sensing is governed by the diffusion equation of magnetoquasistatic fields. As such the eddy current sensor's proximity to the object to be inspected (i.e., “liftoff”) significantly affects the sensor's response signal. Methods and apparatus are disclosed for improving performance for an eddy current sensor, though they may also be used for other sensor types. These solutions are beneficial for both single channel eddy current sensors and arrays, and are particularly beneficial for measuring parts with complex surfaces. In some aspects improved performance is achieved by varying the stiffness of the mechanical support for the sensor. Some mechanical supports may exhibit anisotropic stiffness. After performing a scan with an eddy current array, a multi-channel shape filtering module is applied to improve defect detection. The module reduces the variability of defect response measured due to the unpredictability of the defect location transverse to the scan direction.

The present invention provides an eddy current flaw detection device capable of applying a sufficiently strong magnetic field to a test object without using a significantly large magnet. A magnetic-field forming magnet 60 includes a base magnet piece 60a and a tip magnet piece 60b. The tip magnet piece 60b has a tip pole face 62 from which a magnetic pole is directed toward a test object 30. The tip pole face 62 has a smaller area than a base face 64 of the base magnet piece 60a, the base face 64 being located on the opposite side of the magnetic-field forming magnet 60 from the tip pole face 62.

A method and system for inspecting a steel wheel or steel rim of an off the road vehicle is provided. A method and system for predictive modeling of health and remaining useful life of a steel wheel or steel rim of the off the road vehicle is also provided. The off the road vehicles include vehicles at remote locations such as mine sites.

An in-line inspection (ILI) tool 20 for use inspecting pipelines includes a plurality of collapsible guide centralizers 100 configured and sized to correspond to the inside diameter of the pipeline being inspected. The guide centralizes 100 include wheels 102 roll along the inside wall of the pipeline being inspected to maintain the guide centralizers “centered” within the pipeline. A collapsible exciter unit centralizer 200 is positioned between collapsible guide centralizers 100 to “center” the exciter unit centralizer relative to the interior of the pipeline. The exciter unit centralizer 200 generates signals in the form of an alternating magnetic field that travel along the wall of the pipeline which in turn generates eddy current signals. The eddy current signals undergo a change if a discontinuity in the pipeline is encountered by the inspection tool 20, which signal change or deviation is detected by a collapsible detector unit centralizer 300 positioned between the collapsible guide centralizers 100.

An exemplary method of indicating a condition of grout within a post-tensioned tendon involves positioning a magnet and a metallic sensing plate in close proximity to an outer surface of the post-tensioned tendon; rotating the magnet and the metallic sensing plate around the outer surface of the post-tensioned tendon; measuring an amount of magnetic forces applied to the magnet during rotation of the magnet around the post-tensioned tendon; measuring an impedance between the metallic sensing plate and metallic strands within the post-tensioned tendon during rotation of the metallic sensing plate around the post-tensioned tendon; and generating an image of a cross-section of the post-tensioned tendon indicating one or more grout conditions in spatial proximity to the metallic strands within the post-tensioned tendon based on measurement data using the magnet and the metallic sensing plate.

The invention relates to an eddy current sensor element for non-destructive testing of a substrate, having an assembly of at least a first and a second flat coil, wherein the first flat coil and the second flat coil each have a triangular shape with a first to third coil edge, wherein one of the edges of the first flat coil and one of the edges of the second flat coil are arranged adjacent and parallel to each other, and wherein the assembly has a quadrangular shape. The invention further relates to an eddy current sensor for the non-destructive testing of a substrate, having a plurality of the eddy current sensor elements.

Tubular member end area inspection systems and methods. One system includes a frame, a movable carriage including a magnetic flux generator, and inner and outer detector assemblies. The movable carriage, magnetic flux generator, inner and outer detector assemblies each have an inlet opening for accepting an end area of a tubular member therein and between the inner and outer detector assemblies. The inner and outer detector assemblies each having one or more magnetic or eddy current detectors adapted to be spaced a distance from inner and outer surfaces of the end area of the tubular member. An actuator assembly connecting the frame and the movable carriage includes a sensor adapted to sense an end of the tubular member and direct the movable carriage from a rest position to an inspection position about the end area of the tubular member.

In various aspects, 3D printers, and sensor systems coupled to or integrated with the 3D printers are disclosed. The sensor systems may include image and second sensors for detecting potential defects or print artifacts. During printing, an energy beam source forms a weld pool by melting selected regions of print material, which solidifies to produce the build piece. The image sensor may image an area including the weld pool to determine a landing location of matter ejected during the heating of print material to form the weld pool. The second sensor may detect a defect in the build piece based on the determination of the landing location. Print operation may be suspended while the sensor data is used to repair the defect, after which 3D printing resumes. In this way, for example, high quality build pieces can be produced with reduced post-processing times, and hence a higher manufacturing throughput.

Disclose is a system and method for real-time measurement and feedback of metrology and metallurgical data during additive manufacturing (AM) part fabrication. This solution promises to provide higher performance, lower cost AM parts. A sensor is placed either in the rake/roller or following the rake/roller so that it has no impact on the process efficiency and can be used to provide real-time feedback and an archived digital map of the entire part volume. The solution provides non-contact sensing of AM layer's electrical conductivity in a high-temperature environment, metallurgical property verification, porosity imaging, local defect detection and sizing, local material temperature monitoring, and grain anisotropy imaging. Part geometry, the AM powder, and the laser/material interface are monitored in real-time. Dual mode sensing using magnetoquasistatic and optical sensors enhance results. Real-time nonlinear control of the AM fabrication process is performed based on the sensor data.