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Bridges form a vital link in the physical infrastructure and must be maintained in a "safe working order" at all times. It is estimated that there are currently 20,000 timber road bridges in service throughout Australia. Increasing demands on these bridges due to heavier and faster moving loads, together with deterioration are placing these aging structures at a higher risk of collapse. Unfortunately, many local governments and government departments have neglected the benefits of preventative maintenance and have opted for "just in time" repairs. This is especially true for timber bridges. This past neglect has placed bridge stock in a poor state that is only now being recognised as a significant problem. A key component of this research is to develop improvements to this current situation. This research thesis generates detailed knowledge on the load carrying capacities of timber bridges and new non destructive testing techniques that can be substituted for conventional testing procedures. For the first time guidelines have been developed for undertaking capacity assessment on timber bridges by specifying intervention levels for notched timber and limiting maximum allowable strains in timber members. This newly acquired knowledge will enable Asset Managers to more accurately determine the capacity of sniped timber bridge girders to enable appropriate retrofitting and maintenance while also allowing the safe movement of heavy vehicles. The knowledge generated through destructive testing of timber girders and the analysis of the vast amount of experimental data has enabled the first instance of developing specifications for replacement girders. These specifications detail both functional and performance related targets for three different types of replacement girders. Testing of these replacement girders also demonstrates that through some minor modifications that the specification targets can be met. The outcomes of this thesis provide an innovative approach to accessing the condition and capacity of timber girders and to increasing the safety and life of timber bridges in Queensland. By using new techniques such as Non-destructive testing, species identification and limiting maximum allowable strains, as described in this thesis, the road transport network can be safety used by heavy and permit vehicles. It is only through the effective management of timber bridge maintenance and rehabilitation that Australia can have an efficiently running road transportation network.

CD containing a copy of the thesis, software and extra documentation is held with print copy. / Nuclear Magnetic Resonance (NMR) is a relatively complex technique and normally requires expensive equipment. However, with advances in computing, electronics and permanent magnet technologies, NMR is becoming more feasible as a non-invasive tool for industry. The strength of NMR is its ability to probe at the molecular level and hence gain information about molecular structure, organisation, abundance and orientation. This thesis describes the development of an instrumentation platform technology that is compact and therefore portable. It has been produced to aid the development of NMR based tools or sensors for research and industry and will lead to a series of low cost, portable NMR systems for the non-destructive testing of materials such as polymer composites, rubber, timber, bricks and concrete. The instrumentation is largely electronics based and consists of a series of modules that can be interconnected to produce a solution. The first of two main modules is called the system core. What is common to all NMR applications is the generation of precisely timed signals, the capturing of signals and the processing/display of data. This has been implemented by developing a general purpose Digital Signal Processor (DSP) based instrumentation and control module that uses a Universal Serial Bus interface to communicate with a host computer. A graphical user interface is provided by an application running under Windows® XP. The second main module is a radio frequency transceiver that has been developed using digital receiver technology. The signals, after some amplification, are digitized with a 14-bit, 62.5MH.z analogue to digital converter. The sampled signal is then mixed digitally with synthesized sine and cosine functions to generate lower frequency quadrature outputs which are then digitally filtered and decimated before being passed onto the DSP for further processing and storage. A direct digital synthesizer with an analogue output is used to generate any required excitation signals. All synthesizers have phase and frequency hopping capabilities and are phase locked to each other and the DSP. The system was designed to interface to a range of NMR probes. The type of probe is determined by the intended application and each probe has specific requirements such as the type of radio frequency power amplifier, duplexer and preamplifier needed. This results in a number of instrumentation variations and a modular instrument enclosure was used to cater for these variations. The instrument was first configured for an NMR probe called the NMR-MOUSE. Tests were performed with this probe to verify the correct operation and performance of the instrument. The instrument was then reconfigured for a new probe called the NMR-MOLE and further testing was performed. This probe was still undergoing development and had not been previously tested. Finally, a dedicated compact instrument measuring 360 x 240 x 55 mm and weighing 3.6 kg was developed for the NMR-MOUSE probe.

This research investigates possible monitoring methods to non-invasively detect blockages in the cyclone of milk powder spray driers to avoid costly production shutdowns. Two possible solutions have been identified. These are guided wave and vibration analysis. This research focuses on vibration analysis method, based on variation in the natural frequencies and/or damping ratios caused by blockages. Experimental simulation studies the performance to assess the viability of the vibration analysis method in identifying blockage in the cyclone. To test this method, a 1.87m long vertical cylindrical steel tube with both ends simply supported was setup as a prototype and flour was used as the powder conveyed by the tube. Analytical, numerical and experimental methods were implemented on the prototype using vibration analysis techniques. Experimental resonant frequencies of the empty shell from the impact hammer excitation were compared with analytical and numerical solutions to analyse the modal shapes. The first bending mode was determined as 79 Hz, which decreased with the amount of added mass and location closer to the middle point. This was validated by the simulated mass experiment, which also matched with the beam-mass theory. Flour induced experiment further validated the variation of the first bending mode. Experimental 270Hz, 380Hz and 398Hz resonant frequencies increased with the amount of added mass, which was validated by the simulated mass and flour induced experiment. Besides the variation of the natural frequencies, the damping ratio was also studied and quantified using the Hilbert transform envelope curve method. Onsite monitoring of the vibration of the cyclone in a spray dryer was done at Fonterra Te Rapa and clear resonant frequencies were obtained. The research results from the prototype demonstrate that vibration analysis as a non-destructive method to detect the milk powder deposition or blockage in the cyclone is possible and promising. However, more work is required before industry application.

A systematic and detailed design, building and testing of a high-sensitivity real-time magnetovision imaging system for non-destructive testing (NDT) was the purpose of the research presented here. The magnetic imaging systems developed were all based on an ultra-high sensitivity Quantum Well Hall Effect (QWHE) sensors, denoted as the P2A, which is based on GaAs-InGaAs-AlGaAs 2DEG heterostructures. The research progressed from 0D (single sensor) to 1D (linear array) to 2D (two dimensional arrays) testing modalities. Firstly, the measurement of thermal and shot noises, drift, detection limit, and dynamic offset cancellation of the QWHE sensor were studied in detail to set the framework and limitations of the fundamental QWHE sensors before their eventual use in the imaging systems developed subsequently. The results indicate that the measured data agrees well with calculations for thermal and shot noise when the input bias current is < 3 mA. The measured drift voltages of various QWHE sensors (P2A and P3A) are less than 200 µV when the sensor bias voltage is less than or equal to 2 V. A 4-direction dynamic offset cancellation technique was developed and the results show that the offset equivalent magnetic field of the QWHE sensors can be reduced from ~ 1mT to readings equal to the Earth magnetic field (~ 50 µT). Secondly, a flexible 16 × 1 array and a 32 × 2 staggered array magnetic-field scanners were designed, built, and tested. The QWHE magnetometer had a field strength resolution of 100 nT, and a measurement dynamic range of 138 dB. The flexible 16 × 1 magnetic field scanner can be used to test uneven and/or curved surfaces. This gives the flexible magnetic field scanner better inspection capabilities in both welding hump and circular pipe samples. By the staggered arrangement of two sensor arrays, a 15.4 point per inch horizontal spatial resolution can be achieved for the staggered 32 × 2 magnetic field scanner. Both direct and alternating magnetic flux leakage (DC and AC MFL) tests with the QWHE magnetometer were accomplished to obtain graphical 2-dimensional magnetic field distributions. Both the shape and the location of defects can be identified. The results show that the sensor has high sensitivity and linearity in a wide frequency range which makes it an optimum choice for AC-MFL testing and both ferromagnetic and non-ferromagnetic materials can be investigated. Thirdly, real-time 8 × 8 and 16  16 QWHE array magnetic-field cameras were designed, built, and tested. These prototypes can measure static magnetic field strengths in a 2-dimensional plane. Different shapes of magnets and magnetic field polarities can all be identified by the 8 × 8 magnetic field camera. The camera has a resolution of 3.05 mT, and a dynamic range of 66 dB (the minimum and maximum fields measurable are 3.05 mT and 6.25 mT) and a real time magnetic field measurement rate of 13 frames per second (FPS). By contrast the1616 array magnetic field camera has an improved sampling rate of 600 frame per second and with the use of an interpolation technique, a spatial resolution of 40.6 point per inch can be achieved. The minimum and maximum detectable magnetic field for this magnetic field camera are 1.8 µT and 29.5 mT respectively leading to a record dynamic range of 84 dB for high quality imaging. Finally, a novel, hand held, magnetovision system based on the real-time 16 × 16 QWHE array magnetic-field camera was developed for improved DC and AC electromagnetic NDT testing. The system uses a new super heterodyne technique for data acquisition using the QWHE sensor as a multiplier. This is the first report of such a technique in Hall effect magnetometry. The experimental results of five case studies demonstrate that the defects location and shape can be successfully measured with MFL in DC and AC magnetic field configurations including depth profiling. The major advantages of this real-time magnetic-field camera are: (1) its ease to use as a MFL testing equipment in both DC and AC NDT testing, (2) its ability to provide 2D graphical images similar to Magnetic Particle Inspection (MPI) but without its inherent health and safety drawbacks, (3) its capability to test both ferromagnetic and non-ferromagnetic materials for deep defects below the surface using low frequency alternating magnetic fields, and (4) its ability to identify materials (metals) by alternating external magnetic field illuminations, which has considerable potential in several applications such as security checking and labelling, magnetic markers for analysis, bio-imaging detection, and medical treatments amongst others.

Electromagnetic acoustic transducers (EMATs) are increasingly used in industries due to their attractive features of being non-contact, cost-effective and the fact that a variety of wave modes can be generated, etc. There are two major EMATs coupling mechanisms: the Lorentz force mechanism for conductive materials and the magnetostriction mechanism for ferromagnetic materials; EMATs operated on Lorentz force mechanism are the focus of this study. This work aims to investigate novel efficient modelling techniques for EMATs, in order to gain further knowledge and understanding of EMATs wave pattern, how design parameters affect its wave pattern and based on above propose and optimise novel sensor structures. In this study, two novel modelling methods were proposed: one is the method combining the analytical method for EM simulation and the finite-difference time-domain (FDTD) method for US simulation for studying the Rayleigh waves' properties on the vertical plane of the material; the other one is the method utilizing a wholly analytical model to explore the directivity of surface waves. Both simulations models have been validated experimentally. The wholly analytical model generates the radiation pattern of surface waves, which lays a solid foundation for the optimum design of such sensors. The beam directivity of surface waves was investigated experimentally, and results showed the length of wires has a significant effect on the beam directivity of Rayleigh waves. A novel configuration of EMATs, variable-length meander-line-coil (VLMLC), was proposed and designed. The beam directivity of surface waves generated by such novel EMATs were analytically investigated. Experiments were conducted to validate such novel EMATs models, and results indicated that such EMATs are capable of supressing side lobes, and therefore resulting in a more concentrated surface waves in the desired direction. Further, another two novel configuration of EMATs, the four-directional meander-line-coil (FDMLC) and the six-directional meander-line-coil (SDMLC), were proposed and designed; results showed these EMATs are capable of generating Rayleigh waves in multiple directions and at the same time suppressing side lobes.

Increasing use of composite materials in industry brings the need for newer and more practical methods to evaluate them. Widespread use of composite materials heavily depends on the manufacturer’s ability to unquestionably ensure its safety, given how much the user trusts them. Non-Destructive Evaluation (NDE) can be used to evaluate adhesive bondline health. This thesis employs Digital Image Correlation (DIC) method, one of the known methods in NDE, and combines it with an embedded speckle pattern in order to obtain valuable information from within the adhesive bondline. By recording the movement of the speckles and analyzing their behavior according to DIC algorithms, a strain map of the adhesive is drawn. An adhesive strain map helps find defects that might be out of sight using conventional NDE methods. This thesis discusses different possible materials to be used as the speckle pattern and chooses the one shows better results based on different criteria. Then employing the material, it records the speckle pattern using optical and ultrasonic methods to draw a strain map. By analyzing the obtained strain maps, defects within the bondline are revealed.

Sistemas de ensaios não destrutivos por ondas guiadas despertam cada vez mais a atenção tanto da indústria, como da academia. Isso deve-se, principalmente, às possibilidades que as ondas guiadas permitem, como maior área de triagem que o ultrassom convencional. Porém a técnica tem suas limitações, já que esta apenas gera uma estimativa da localização de um defeito e não a sua dimensão. Nessa limitação, algoritmos tomográficos apresentam uma possibilidade de avanço da técnica, pois permitem determinar não só a localização de corrosões e defeitos, mas também seu dimensionamento. Este trabalho apresenta tomografia de difração como uma alternativa para avaliação de integridade estrutural. Primeiramente, utilizou-se análise por métodos numéricos para mostrar a validade dos algoritmos e posteriormente foi realizado um experimento em uma chapa real com o objetivo de reconstruir a imagem do defeito. / Guided waves nondestructive testing systems are increasingly attracting industrial and academic attention. The mainly reason for this attention is the possibility of screening a large area than conventional ultrasound technique. However, Guided Waves Testing has limitations, since it gives only an estimation of the location of a defect, but not the dimensions. Tomographic algorithms come up with an improvement of the technique, because it allows discovery not only the location of corrosions and defects, but the dimensions too. This work brings Diffraction Tomography as an alternative to structural health monitoring. First, a numerical analysis was implemented to demonstrate the validity of the algorithms, after that an experiment in a real plate was made with the objective to recover the defect image.

A operação segura e eficiente em unidades de produção de petróleo e gás depende do desempenho de seus dispositivos, componentes e estruturas. Dutos rígidos são importantes componentes utilizados na indústria offshore, comumente empregados como flowlines e risers. Durante a vida em serviço destes componentes, eles sofrem tensões axiais cíclicas associadas a sua movimentação, ao processo de extração de petróleo e ao vórtice das marés. O aço inoxidável superduplex surgiu na última década como um material alternativo para ambientes quimicamente agressivos, mas quando catodicamente protegidos contra a corrosão, esses aços são vulneráveis a fragilização por hidrogênio. Este trabalho tem como objetivo, através da técnica de Ensaio Não Destrutivo de ultrassom phased array, monitorar o crescimento de defeitos internos e externos criados intencionalmente próximos à raiz e ao reforço da solda de um tubo de aço superduplex (UNS S32750) de 6´´ submetido a fadiga tração-tração e fragilização induzida por hidrogênio devido à proteção catódica. As inspeções foram realizadas periodicamente com varreduras de 30 a 75° ao longo da circunferência da solda, por um transdutor linear 1-D de 16 elementos e 5MHz acoplado a uma sapata de 36°. Os resultados obtidos foram utilizados para alimentar análises de integridade estrutural, obtenção da curva da/dN x ΔK. / Safe and efficient operation in oil and gas production units depends on the performance of your devices, components and structures. Rigid pipelines are important components in the offshore industry, common used as flowlines and risers. During a life in service of components, they suffer cyclical axial stresses associated with their movement, by the oil extraction process and tidal vortex. Super duplex stainless steel has emerged in the last decade as an alternative material for chemically aggressive environments, but when cathodically protected against corrosion, it is vulnerable to hydrogen embrittlement. This work aims to, through the ultrasonic non-destructive testing by phased array monitor the growth of internal and external defects created intentionally close to the root and reinforcement of the weld of a superduplex steel tube (UNS S32750) with diameter of 6" submitted to tensile-traction fatigue and hydrogen-induced embrittlement due to cathodic protection. The inspections were performed periodically with 30 to 75° scans along the circumference of the weld, by a linear transducer of 1-D, 16-element and 5MHz coupled to a wedge of 36°. The obtained results were used to feed structural integrity analyzes, obtaining the curve of da/dN x ΔK.

Componentes metálicos em operação podem estar sujeitos a diversas condições de operação deletérias. Visando avaliar os riscos de operação para evitar falhas, a análise de integridade estrutural é uma ferramenta amplamente aplicada e requer constante evolução. Por utilizar dados de ensaios não destrutivos, essa ferramenta requer cada vez mais precisão, para aprimorar seus resultados e reduzir ao máximo as falhas de componentes em operação. Por apresentar menor tempo de inspeção e maior probabilidade de detecção, o Phased Array surge como alternativa às técnicas convencionais de ultrassom. Dentre as técnicas de Phased Array, o Total Focusing Method (TFM) apresenta um dos resultados mais promissores, apresentando grande vantagem sobre técnicas convencionais de ultrassom e de Phased Array devido a sua melhor precisão e fácil interpretação dos resultados. Neste trabalho, o TFM foi aplicado em diversos blocos contendo descontinuidades usinadas, as quais simulam diferentes tipos de defeitos. O foco do TFM foi gerar blocos em três dimensões (3D) dos defeitos, facilitando a interpretação dos resultados, além da possibilidade da inserção desses blocos em softwares de análise de integridade estrutural, melhorando a precisão dos resultados. O TFM foi aplicado através do tratamento de dados de um sensor linear de Phased Array, com frequência de 5 MHz e com 64 elementos ativos. Nesse trabalho, foram desenvolvidas e aplicadas novas etapas no algoritmo do TFM para melhorar a precisão dos resultados, como a compensação da perda de energia e o half-skip. As etapas adicionais aplicadas ao algoritmo do TFM geraram bons resultados para entalhe e furos usinados nos blocos de aço carbono. Além dos blocos com defeitos usinados, foi realizada a inspeção de um bloco de aço inoxidável austenítico soldado. Para o bloco soldado, os resultados não foram satisfatórios, não sendo possível detectar defeitos existentes. Após a aplicação do TFM, foi simulado o deslocamento do sensor ao longo da peça, gerando diversas imagens 2D, as quais foram conectadas via isosuperfícies, gerando sólidos 3D dos defeitos presentes em cada bloco. Por fim, esses blocos foram exportados para um software CAD, apresentando excelente correspondência. / Metallic components in operation can be submitted to several harming operation conditions. Aiming to evaluate the operational risks to avoid failure, the structural integrity analysis is a widely applied tool and requires constant evolution. As it uses non-destructive testing data, this tool requires increasingly precision, to enhance its results and reduce the majority of the operating components failures. Because of the shorter inspection time and greater probability of detection, Phased Array is an alternative to conventional ultrasonic techniques. Among the techniques of Phased Array, the Total Focusing Method (TFM) presents one of the most promising results, offering great advantage over conventional ultrasonic and Phased Array techniques due to its better precision and easy interpretation of results. In this work, the TFM was applied to many blocks, which contain machined discontinuities simulating several defects. The objective of applying the TFM was to generate three-dimensional (3D) blocks, turning the interpretation of the results easier and giving the possibility to insert these blocks into a structural integrity analysis software, enhancing the results precision. The TFM algorithm was applied through treatment of data from a 5 MHz linear Phased Array sensor with 64 active elements. In this work, it were developed and applied new steps in the TFM algorithm, as energy loss compensation and half-skip interaction, to improve its precision. The additional steps applied to the TFM algorithm achieved great results for notch and holes machined in carbon steel blocks. In addition to the blocks with machined defects, a welded austenitic stainless steel block was inspected. For the welded block, the results were not satisfactory and it was not possible to detect the present defects. After the application of the TFM, the displacement of the transducer along the block was simulated, generating several 2D images, which were connected via isosurfaces, generating 3D solids corresponding to the defects present in each block. To conclude, these blocks were exported to a CAD software, presenting excellent matching.