Session: Research Posters

Paper Number: 170586

Ultrasonic Simulation and Experimental Total Focusing Method Inspection Method for Precision Crack Characterization in Aws D 1.5- Compliant Weldments 

Cracks are the most critical welding defects as it causes severe structural failure which can cost lives and permanent damage to the property. Infrastructure failure like I-40 bridge disaster are real life example of how cracks are dangerous to heavy structural components like steel bridges. Even AWS also has enhance and inflexible guidance regarding the cracks in weld, as any cracks no matter how big or small it is should be rejected. There are different types of weld cracks and each cracks have significant structural impact on infrastructures. Transverse cracks can weaken the load-bearing capacity and it propagates rapidly under cycling loading which leads to brittle fracture or fatigue fracture. At the same time root cracks which is located at the bottom of the weld compromises the bond between weld parts which undermines joint integrity. These cracks are difficult to detect with conventional Phased Array Ultrasound Testing and if a crack is remain undetected it can cause severe harm to the structural integrity. Detecting and characterizing these anomalies is imperative and for that advanced techniques should be applied. Ultrasonic simulation analysis can facilities the study of wave interaction with planar defects like cracks. In this simulation method realistic geometrics of welds and defects can be constructed which helps in visualizing how ultrasonic beam reflect, refract or scatter when it interacts with flaws. It also supports the assignment of proper material properties that it needed to replicate real world Ultrasound inspection environment. And more importantly the simulations provide time-domain waveforms which allows prediction of defect depths and echo patterns. At the same time Total Focusing method offers a significant advancement over conventional PAUT in detection of planar defects because of its usage of Full matrix Capture data instead of pre-defined focal laws like PAUT.  Because of this, TFM achieves sub-millimeter resolution (as fine and 0.5 mm). TFM minimizes acoustic artifacts and noise which improves defect boundary clarity and aiding in precise sizing and it also generates high-contrast image, which can distinguish between crack-like signals and benign indications such as geometry echoes or other inclusions. So, by integrating advanced simulations with TFM inspections this methodology establishes a synergic workflow; simulation guides optimal TFM setup while experimental validation using real world specimens confirms defect detection accuracy. This combined approach enhances the reliability, resolution and AWS D 1.5 –compliance of crack detection protocols which ensures both theoretical and practical robustness in characterization of critical weld flaws.

Presenting Author: Chowdhury Irtiza Georgia Southern University

Presenting Author Biography: I am a Graduate Mechanical Engineer currently working as a Graduate Research Assistant at Georgia Southern University's LANDTIE Lab. I am pursuing my master’s in advanced engineering at the same university, with a focus on structural health monitoring of welded components using advanced non-destructive testing (NDT) methods such as Phased Array Ultrasonic Testing (PAUT). My research involves analyzing and characterizing defects, conducting root cause analysis, and optimizing process parameters in accordance with AWS D1.5 standards.

Prior to my graduate studies, I worked for three years as an R&D Engineer in a compressor manufacturing facility, where I was responsible for new product development, designing molds and tooling for mass production, and conducting root cause analysis to improve product quality and manufacturing efficiency. My role also included design optimization and simulation analysis to ensure the feasibility of prototypes for large-scale production.

Additionally, I am a Certified SolidWorks Professional with expertise in Mechanical Design, Mold Design, Advanced Surfacing, and Sheet Metal Industry applications.

Authors:

Chowdhury Irtiza Georgia Southern University
Bishal Silwal Goergia Southern University
Hossein Taheri Georgia Southern University