Thesis

Optimisation of weld inspection processes using advanced simulation tools

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Awarding institution
  • University of Strathclyde
Date of award
  • 2026
Thesis identifier
  • T17605
Person Identifier (Local)
  • 201692089
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Qualification Name
Department, School or Faculty
Abstract
  • The application of Non-Destructive Testing (NDT) techniques for the inspection of welded structures are widely used across many engineering industries. Inspection of weld joints is an essential component of structural assessment as it allows fatigue analysis to be carried out to quantify structural integrity and approximate remaining life span. A prominent methodology used for detecting and sizing defects within welded structures is ultrasonic inspection. An advanced ultrasonic technique, commonly implemented for weld inspection due to its robustness and adaptability is Phased Array Ultrasonic Testing (PAUT). To complement the generation of inspection plans, the use of NDT modelling packages, such as CIVA, is increasing in popularity. They are particularly appealing when dealing with welded structures that have complications such as complex weld/structure geometries, limited surface accessibility or difficulties between the angle of propagation and flaw orientations. In such cases, identical test specimens of the in-situ structures can be made for lab-based analysis. However, these specimens can come at huge expense, have extensive manufacturing periods, require storage space, and cannot be altered once the structure has been made. For such structures, modelling packages can simulate inspection setups by recreating the weld geometries from CAD files, the user can select from a library of probes, position/orientate flaws in any given location, and run parametric studies of varying inspection setups and/or flaw settings. To guarantee that inspection simulations are fully representative of a physical inspection, the simulation must also be calibrated in the same manner as used in a physical examination. This ensures that the approximated amplitude responses acquired for a given flaw are fully representative of what would be achieved in an in-situ examination. This thesis presents the development of a custom script and process that will allow inspection simulations to be calibrated in a similar manner to physical inspections. The efficacy of the approach for known flaws is demonstrated by its comparison to expected results and the results achieved by alternate approaches to recreate the same calibration method. Further enhancement to the procedure and custom script showed improved approximation capabilities when implemented for insitu flaws.
Advisor / supervisor
  • Gachagan, Anthony
  • O'Leary, Richard
Resource Type
DOI
Date Created
  • 2025
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