The growth of the automated welding sector and emerging technological requirements of Industry 4.0 have driven demand and research into intelligent sensor-enabled robotic systems. The higher production rates of automated welding have increased the need for fast, robotically deployed Non-Destructive Evaluation (NDE), replacing current time-consuming manually deployed inspection. This paper presents the development and deployment of a novel multi-robot system for automated welding and in-process NDE. Full external positional control is achieved in real time allowing for on-the-fly motion correction, based on multi-sensory input. The inspection capabilities of the system are demonstrated at three different stages of the manufacturing process: after all welding passes are complete; between individual welding passes; and during live-arc welding deposition. The specific advantages and challenges of each approach are outlined, and the defect detection capability is demonstrated through inspection of artificially induced defects. The developed system offers an early defect detection opportunity compared to current inspection methods, drastically reducing the delay between defect formation and discovery. This approach would enable in-process weld repair, leading to higher production efficiency, reduced rework rates and lower production costs.

The demand for cost-efficient manufacturing of complex metal components has driven research for metal Additive Manufacturing (AM) such as Wire + Arc Additive Manufacturing (WAAM). WAAM enables automated, time- and material-efficient manufacturing of metal parts. To strengthen these benefits, the demand for robotically deployed in-process Non-Destructive Evaluation (NDE) has risen, aiming to replace current manually deployed inspection techniques after completion of the part. This work presents a synchronized multi-robot WAAM and NDE cell aiming to achieve (1) defect detection in-process, (2) enable possible in-process repair and (3) prevent costly scrappage or rework of completed defective builds. The deployment of the NDE during a deposition process is achieved through real-time position control of robots based on sensor input. A novel high-temperature capable, dry-coupled phased array ultrasound transducer (PAUT) roller-probe device is used for the NDE inspection. The dry-coupled sensor is tailored for coupling with an as-built high-temperature WAAM surface at an applied force and speed. The demonstration of the novel ultrasound in-process defect detection approach, presented in this paper, was performed on a titanium WAAM straight sample containing an intentionally embedded tungsten tube reflectors with an internal diameter of 1.0 mm. The ultrasound data were acquired after a pre-specified layer, in-process, employing the Full Matrix Capture (FMC) technique for subsequent post-processing using the adaptive Total Focusing Method (TFM) imaging algorithm assisted by a surface reconstruction algorithm based on the Synthetic Aperture Focusing Technique (SAFT). The presented results show a sufficient signal-to-noise ratio. Therefore, a potential for early defect detection is achieved, directly strengthening the benefits of the AM process by enabling a possible in-process repair.

Inspection of components with surface discontinuities is an area that volumetric Non-Destructive Testing (NDT) methods, such as ultrasonic and radiographic, struggle in detection and characterisation. This coupled with the industrial desire to detect surface-breaking defects of components at the point of manufacture and/or maintenance, to increase design lifetime and further embed sustainability in their business models, is driving the increased adoption of Eddy Current Testing (ECT). Moreover, as businesses move toward Industry 4.0, demand for robotic delivery of NDT has grown. In this work, the authors present the novel implementation and use of a flexible robotic cell to deliver an eddy current array to inspect stress corrosion cracking on a nuclear canister made from 1.4404 stainless steel. Three 180-degree scans at different heights on one side of the canister were performed, and the acquired impedance data were vertically stitched together to show the full extent of the cracking. Axial and transversal datasets, corresponding to the transmit/receive coil configurations of the array elements, were simultaneously acquired at transmission frequencies 250, 300, 400, and 450 kHz and allowed for the generation of several impedance C-scan images. The variation in the lift-off of the eddy current array was innovatively minimised through the use of a force–torque sensor, a padded flexible ECT array and a PI control system. Through the use of bespoke software, the impedance data were logged in real-time ($\le$7 ms), displayed to the user, saved to a binary file, and flexibly post-processed via phase-rotation and mixing of the impedance data of different frequency and coil configuration channels. Phase rotation alone demonstrated an average increase in Signal to Noise Ratio (SNR) of 4.53 decibels across all datasets acquired, while a selective sum and average mixing technique was shown to increase the SNR by an average of 1.19 decibels. The results show how robotic delivery of eddy current arrays, and innovative post-processing, can allow for repeatable and flexible surface inspection, suitable for the challenges faced in many quality-focused industries.

Performance of modern robotic manipulators has enabled research and development of fast automated non-destructive testing (NDT) systems for complex geometries. This paper presents recent outcomes of work aimed at removing the bottleneck due to data acquisition rates, to fully exploit the scanning speed of modern 6-DoF manipulators. State of the art ultrasonic instrumentation has been integrated into a large robot cell to enable fast data acquisition, high scan resolutions and accurate positional encoding. A fibre optic connection between the ultrasonic instrument and the server computer enables data transfer rates up to 1.6GB/s. Multiple data collection methods are compared. Performance of the integrated system allows traditional ultrasonic phased array scanning as well as full matrix capture (FMC). In FMC configuration, linear scan speeds up to 156mm/s with 64 pulses per frame are achieved - this speed is only constrained by the acoustic wave propagation in the component. An 8x increase of the speed (up to 1.25m/s) can be achieved using multiple transmission elements, reaching the physical limits for acceptable acoustic alignment of transmission and reception paths. Scan results, relative to a 1.2m × 3m carbon fibre sample, are presented.