The present invention relates to an integrated system and method for in-situ 3-axis scanning and detecting defects in a CFRP composite (150) being loaded under static and cyclic test conditions. The system comprises a test system integrated with (10) a scanning system (20) that comprises a probe assembly (52) to generate eddy current on the surface of the CFRP composite (150) mounted on the test system, and a 3D scanner assembly (60) for movement of the probe assembly (50) over the entire surface area of the CFRP composite (150) along X-axis, Y-axis and Z-axis. An operator console (70) is connected to the test system and the scanning system (20) for controlling (3) mechanical test process in the test system and for controlling 3-dimensional movement of the probe assembly (52) along X-axis, Y-axis and Z-axis in a synchronous manner. Such system and method achieve (3D) automated and synchronized 3D scanning of the CFRP composite (150) to accurately detect the defects in the CFRP composite (150) before/during/after mechanical testing without interrupting the mechanical test process.

A robotic inspection system for bridge suspender cables includes a sensing device and a transport vehicle. The transport vehicle is configured to move the sensing device along a bridge suspender cable for taking main magnetic flux (MMF) readings as the sensing device moves along the bridge suspender cable. The system also includes a control station configured to wirelessly interface with the sensing device and the transport vehicle. In addition, the control station is configured to generate a bridge cable condition assessment report from the MMF readings to identify locations and sizes of deterioration of the bridge suspender cable.

A technique facilitates examination of a tubing string. A sensor is mounted to monitor a pipe for a defect or defects. The sensor outputs data on the defect to a data processing system which identifies the type and severity of the defect. The data processing system also may be used to track the defect to determine changes to the defect during, for example, subsequent uses of the pipe. Based on the evaluation of the defect, recommendations are provided with respect to future use or handling of the pipe.

The invention concerns a method for additive manufacturing a component by repetitively superposing and solidifying material layers according to a 3D model of the component. The method comprises the steps of scan, by means of an eddy current sensing unit (20), of a new solidified cross section (15) obtained by selectively solidifying a material layer so as to provide an integrity data (VMM) of a sensed portion (23). A difference between the sensed integrity data (VMM) and an expected integrity data (VEE) is then executed for detecting a manufacturing anomaly within this portion. The expected integrity data (VEE) is determined based on collected integrity data of a solid basic structure likely matching or being identical to a geometrical structure (41) obtained from the 3D model (40) of a portion corresponding to said sensed portion (23), said solid basic structure being manufactured or simulated according to another 3D model.

A damage evaluation apparatus, to evaluate damage to a tendon embedded in concrete. The apparatus includes a magnetizer for generating magnetic force, and a detector for detecting change in magnetism produced from a damaged area of the tendon when magnetized. The magnetizer includes a excitation coil; an iron core passing through a center hole of the excitation coil; a pair of columnar yokes connected to respective ends of the iron core and extending toward the concrete; and a pair of plate-shaped yokes connected to the pair of columnar yokes at a distal end thereof for forming magnetic poles having spread along the surface of the concrete. By passing an electric current through the excitation coil, a magnetic circuit is formed by the yoke shaft, the pair of columnar yokes, the pair of plate-shaped yokes, and the tendon over a range thereof situated between the pair of plate-shaped yokes.

A damage evaluation apparatus, which is used on a concrete structure having an embedded tendon to be evaluated for damage. The damage apparatus includes a magnetizer for generating magnetic force, and a detector for detecting a change in magnetism produced from a damaged area of the tendon. The magnetizer includes an excitation coil; an iron core passed through a center hole of the excitation coil; and a pair of columnar yokes connected to respective ends of the iron core and each extending toward the surface of the concrete. By passing an electric current through the excitation coil, a magnetic circuit is formed by the yoke shaft, the pair of columnar yokes, and the tendon over a range thereof situated between a pair of plate-shaped yokes. Current that flows through the excitation coil is controlled such that the magnetic flux density of the tendon is rendered constant.

A distance sensor unit is also provided. The distance sensor unit includes an array of distance sensors configured to identify surface irregularities deviating from an expected nominal geometry of a surface as the distance sensor unit is moved along the surface and a handheld housing configured for being gripped by an operator. The array of distance sensors is connected to the handheld housing. The distance sensor unit also includes at least one surface irregularity indicator configured for providing an alert to the operator as the distance sensor unit moves over one of the surface irregularities deviating from the expected nominal geometry of the surface.

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.

An untethered in-line inspection tool for the non-destructive testing of a tubular test component is described which comprises one or more partial saturation eddy current testing (PSET) modules configured to locate with an internal surface of the test component. The one or more PSET modules comprise a variable strength permanent magnet for generating a variable DC magnetic field within the test component and at least one eddy current sensor. Having an in-line inspection tool that employs PSET techniques allows the in-line inspection tool to operate with an increased range of pipeline types. For the detection of cracks the in-line inspection tool may also comprise one or more crack detection modules. The in-line inspection tool further comprises one or more battery modules. Employing a dedicated battery module removes any need to employ an umbilical or wireline in order to provide power to one or more electromagnets.

A drive coil assembly to generate a specific spatial distribution of eddy currents within the walls of a conductive tube or pipe, which may be used in conjunction with a separate array of magnetic sensors to detect defects in the tubing wall. The drive coil assembly comprises a plurality of coils which are generally wrapped around the circumference of a cylindrical probe body, but which are further shaped with serpentine undulation in the axial direction. The undulation is characterized by a spatial amplitude, a spatial phase and a spatial frequency; typically, the spatial frequency results in an integer number of undulations around the circumference of the drive coil and the phase is chosen to uniformly distribute the lobes about the circumference. The temporal phase of the electrical current in each coil is chosen to null out net current of the assembly around the circumference.