Nondestructive Evaluation 4.0

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Nondestructive Evaluation 4.0 (NDE 4.0) is the concept of cyber-physical non-destructive evaluation (including nondestructive testing) arising from Industry 4.0 digital technologies, physical inspection methods, and business models. It seeks to enhance inspection performance, integrity engineering and decision making for safety, sustainability, and quality assurance, as well as provide timely and relevant data to improve design, production, and maintenance characteristics.

NDE 4.0 arose in response to the concept of the Fourth Industrial Revolution, which can be traced to the development of a high-tech strategy for the German government in 2015, under the term Industrie 4.0,, which became widely known in 2016 following its adoption as the theme of the World Economic Forum annual meeting in Davos.

The concept gained strength following the opening of the Center for the Fourth Industrial Revolution in 2016 in San Francisco. NDE 4.0 evolved in conjunction with Industry 4.0. It is recognized as a future goal by several global NDE organizations: the International Committee for Nondestructive Testing (ICNDT) has a Specialist international Group (SIG) on NDE 4.0, and the European Federation for Nondestructive Testing (EFNDT) created a working group designated as "EFNDT Working Group 10: NDE 4.0" (WG10). The importance of NDE 4.0 is reflected in the activities of NDE organizations throughout the world, including the American Society of Nondestructive Testing (ASNT), through publications and training.

History

Leading to NDE 4.0, just as those leading to Industry 4.0 were prior developments that are divided into prior revolutions based on distinct technological markers. These are usually defined for industry and hence for nondestructive evaluation.

NDE 1.0. The first revolution in nondestructive evaluation coincides with the first industrial revolution and refers to the period between approximately 1870 (following the invention of the Watt’s steam engine in 1769) and 1870. The transition from hand and artisanal production and “muscle power” to mechanized production and steam- and hydro-power necessitated the introduction of nondestructive testing. Prior to this period, people have tested objects for thousands of years through simple methods based human sensory perception – feeling, smelling listening and observing as appropriate. The development in the first industrial revolution gave birth to non-destructive inspection through the introduction of tools that sharpened the human senses, and through tentative attempts at standardized procedures. Tools such as lenses, colors or stethoscopes, tap and listen procedures and others, improved detection capabilities. Establishing procedures, made the outcome of the inspection comparable over time. At the same time, industrialization also made it necessary to expand quality assurance measures, a process that continues to this day.

NDE 2.0. The second revolution in NDE is commonly referred to as the period between 1870, with the appearance of first means of mass production, marked by the introduction of the conveyor belt, and 1969. As with the second revolution in industry, it is characterized by use of physical, chemical, mechanical and electrical knowledge to improve testing and evaluation. The transformation of electromagnetic and acoustic waves, which lie outside the range of human perception, into signals that can be interpreted by humans, resulted in a “look” into the components or a better visualization of material inhomogeneities at or close to the surface. Following the discovery of X-rays in 1895, it became a dominant method for testing, followed by gamma-ray testing. With the introduction of the transistor into electronics, testing methods such as ultrasound developed further into lighter, portable systems suitable for field testing. The first detectors for infrared and terahertz detection were invented around the same time and the first eddy current devices became available. Although these were critical methods of testing that persist to this day, further breakthroughs had to wait until digitization and digital electronics developed in the third NDE revolution.

NDE 3.0. The third revolution in NDE parallels the advent of microelectronics, digital technologieds and computers. It is usually thought of as the period starting in 1969, marked by the introduction of the first programmable logic controller (PLC), and 2016. Digital inspection equipment, such as X-ray detectors, digital ultrasonic and eddy current equipment, and digital cameras became integral parts of the system of testing and evaluation. Robotics lead to automated processes, improving convenience, safety, speed and repeatability. Digital technologies offered leaps in managing inspection data acquisition, storage, processing, 2D and 3D imaging, interpretation, and communication. Data processing and sharing became the norm. At the same time, these developments created new challenges and opportunities such as data security and integrity and introduced new concepts such as value of data and its monetization.

NDE 4.0. The fourth revolution in NDE integrates the digital techniques (from the third) and physical methods of interrogating materials (from the second) in a closed loop manner transforming human intervention and enhancing inspection performance. Within the context of the physical-digital-physical loop of NDE 4.0; digital technologies and physical methods may continue to evolve independently, interdependently, or concurrently. The real value is in concurrent design of inspection through application of Digital Twins and Digital Threads. This provides the ability to capture and leverage data right from materials and manufacturing processes to usage and in-service maintenance. The data captured across multiple assets, can be used to optimize predictive and prescriptive maintenance, repairs and overhauls over the lifetime of an asset. The relevant data can be fed back to OEM for design improvements. NDE 4.0 also serves the emerging trends in custom manufacturing. Remote NDE can keep the inspector away from harm’s way and integration by “tele-presence” can bring additional specialists in the decision process from anywhere in the world quickly and affordably.

Drivers and Components of NDE 4.0

The overarching driver of NDE 4.0 is the same as that of the fourth industrial revolution – the integration of digital tools and physical methods, driven by current digital technologies through introduction of new ways of digitalization of specific steps in NDE processes, with a promise of overall efficiency and reliability. There are three recognizable components of NDE 4.0. First, Industry 4.0 emerging digital technologies can be used to enhance NDE capabilities in what has been termed  “Industry 4.0 for NDE”. Second, statistical analysis of NDE data provides insight into product performance and reliability. This is a valuable data source for Industry 4.0 to continuously improve the product design in the “NDE for Industry 4.0” process. Third, immersive training experiences, remote operation, intelligence augmentation, and data automation can enhance the NDE value proposition in terms of inspector safety and human performance in the third component of NDE 4.0 – the “Human Consideration”.

Industry 4.0 for NDE - Enhancing NDE Capability and Reliability through Emerging Technologies

A significant contribution of Cyber-Physical NDE system (NDE 4.0) stems from the better control or partial elimination of human factors in probability of detection (POD) leading to a more reliable inspection system, i.e., better Probability of Detection (POD) and a more consistent POD from inspection to inspection. As a result, inspection programs can be optimized, saving time, money, and improving asset availability. The entire inspection process can be made more effective and efficient through use of digital workflow control and tracking. Component traceability requires the need to ensure that the correct component was inspected, the documentation is revision-safely stored, and the results can easily be retrieved. Revision-safe data storage can be implemented by using blockchains and the component identification by digital component files and electronic component identifiers. Digital workflows enables value stream efficiency: task allocation from the customer to the inspector and the results transferred back to the customer. Data transfers are performed using IIoT technologies and interfaces. Digital commissioning also allows transfer of order-related information using standard IIoT interfaces. With the implementation of digital supply chain processes both to customers and suppliers using standard interfaces a complete digital workflow can be established enabling NDE Processes 4.0.

NDE 4.0 for Industry - Improving Industry Processes Through Feedback and Feedforward NDE Data.

NDE result statistics from production and in-service inspections, feedback loops from destructive tests, component acceptance, and EOL component testing, help quality assurance personnel to get a better appreciation of the value of the inspections. This data can also provide insight into system performance and reliability. Usage statistics or inspection performance evaluations can show the need for a certain inspection on one hand and identify human factor influences on the other hand. This should help reduce operator dependence, inspection inconsistencies, and need for additional training or process change. Such evaluations can also be used to monitor training, experience hours for personnel evaluation, qualification, and certification. If required and permitted by local law, it can even indicate the mental state of inspectors, to provide support elements to improve their conditions such as stress monitoring or fatigue. Feedback from NDE 4.0 processes can also be used to improve NDE equipment by providing the data-like error codes, system parameters, system status information, software exceptions/errors, or use or misuse of equipment to NDE equipment developers. Similarly, statistical evaluation of user behavior helps improve the user interface design, training, and applicability. This feedback loop may also contribute to accelerated troubleshooting and improvements of inspection equipment as a competitive advantage.

Improving Inspector Safety and Inspection Support Through Remote Access

Remote support or TeleNDE by equipment manufacturers or other experienced inspectors/engineers can mitigate several challenges. Such remote support solutions or remote-controlled robot/drone-based equipment can be enabled by extended reality platforms and connected devices. Remote support by equipment manufacturers at the inspection location, in particular in hard-to-reach locations, could be a huge help to the inspectors and a money saver for the inspection service providers. At the same time, it is an opportunity for the manufacturer to investigate/reproduce potential issues/bugs with the equipment, if any. Remote support by other inspectors can help in inspection situations where a second opinion is needed, were an in-depth evaluation of indications identified by the inspector at location needs to be conducted and where local (potentially inexperienced) inspection personnel must be used (for example due to travel restrictions). Such remote support scenarios can be expanded by engineers inside and outside of NDE. This can be taken to extreme by remote control of aerial drones or underwater robot-based inspection systems.

NDE for Everybody – The Promise of Connected Devices

Powerful and widely available electronic devices, such as tablet computers and cellphones, incorporate various sensors in the form of cameras, microphones, vibration sensors and accelerometers. Other smartphone attachable tools are available for purchase including IR cameras, terahertz arrays, eddy current transducers that can be used for household NDE. The use of these tools is as simple as downloading an application and attaching the removable device to the phone. That is literally everything that is necessary to start taking measurements. This will make the whole world’s accumulated knowledge (that is, a large amount of data) available to anyone at any time and any place. Merging the highly specialized knowledge of NDE techniques with current technology will open a new market for NDE 4.0. These new hand-held devices will be applied to make NDE available and affordable to anybody. As a benefit, product inspection at home can become an additional component of monitoring the life cycle of a product. This might significantly increase the acceptance of NDE 4.0 by solving new inspection problems for everyday services.

Definitions and their relations to NDE 4.0.

NDE 4.0 relies on and encompasses a variety of xxxxx including digital technologies, data constructs, communication, business, organizational and financial aspects as well as security, knowledge and personnel competencies, various stakeholder and processes. Many of these are generic in nature, some are shared with Industry 4.0 and some are unique to NDE 4.0. These are defined as follows:

• Digitization: The process of using digital technologies on digitized data to simplify and automate business operations. Means of converting hard-copy or non-digital records, analog signals into digital format.
• Digitalization: Digitalization is the use of digital technologies to change a model (such as a business or social model) and provide new revenue and value-producing opportunities; it is essentially the process of moving to a digital business in the broader sense of “business”
• Digital transformation: This the process of using digital technologies to improve processes, productivity, value generation, organizational culture and customer experiences. Digital transformation  is related to the profound and accelerating transformation of business activities, processes, competencies and models to fully leverage the changes and opportunities of digital technologies and their impact in a strategic and prioritized way. Digital transformation comprises three phases: digitization (the core of the third revolution), digitalization (the transitional process to the fourth industrial revolution and digital transformation proper as the core of the fourth revolution.
• Digital thread: Digital thread is the use of digital tools and representations for design, evaluation, and life cycle management. It refers to the communication framework that allows a connected data flow and integrated view of the asset’s data throughout its lifecycle across traditionally siloed functional perspectives.
• Digital twin: A digital twin is a virtual representation of an intended or actual real-world physical object or system that spans its lifecycle, is updated from real-time data, and uses simulation, machine learning and reasoning to help decision-making. The digital twin serves as the effectively indistinguishable digital counterpart of it for practical purposes, such as simulation, integration, testing, monitoring, and maintenance.

• NDE Ecosystem: The NDE ecosystem is the network of organizations—including suppliers, distributors, customers, competitors, government agencies, and so on—involved in the exchange of inspection equipment, training, data, or service through competition, cooperation, or regulation for the purpose of assuring safety and quality.

• Informatization: Informatization is the process by which information technologies, such as the World Wide Web and other communication technologies, have transformed economic and social relations to such an extent that cultural and economic barriers are minimized
• Semantic interoperability: The ability of computer systems to exchange data with unambiguous, shared meaning.

• DICONDE: Digital Imaging and Communication for Nondestructive Evaluation (DICONDE) is is an open standard format for the display, transfer and storage of digital NDE data. It facilitates the display of NDE signal and image data on different systems that conform to the DICONDE format. At its essence, DICONDE provides a vendor-neutral digital data storage and transmission protocol that defines the organization of nondestructive testing (NDT) inspection data and associated metadata in a standard format. DICONDE is based on and inherits from the universally adopted medical standard, DICOM, which facilitates the interoperability of imaging, video, and signal data acquisition equipment through data storage, query, and network communication protocols.
• Data Monetization: Refers to the process of using data to obtain quantifiable economic benefit. Internal or indirect methods include using data to make measurable business performance improvements and inform decisions. External or direct methods include data sharing to gain beneficial terms or conditions from business partners, information bartering, selling data outright (via a data broker or independently), or offering information products and services (for example, including information as a value-added component of an existing offering).
• https://www.gartner.com/en/information-technology/glossary/data-monetization
• Industrial Internet of Things (IIoT): The industrial internet of things (IIoT) refers to interconnected sensors, instruments, and other devices networked together with computers' industrial applications, including manufacturing and energy management. This connectivity allows for data collection, exchange, and analysis, potentially facilitating improvements in productivity and efficiency as well as other economic benefits. The IIoT is an evolution of a distributed control system (DCS) that allows for a higher degree of automation by using cloud computing to refine and optimize the process controls.
• Ideation: Ideation refers to the process of developing and conveying prescriptive ideas to others, typically in a business setting. It describes the sequence of thoughts, from the original concept to implementation. Ideations can spring forth from past or present knowledge, external influences, opinions, convictions, or principles. Ideation can be expressed in graphical, written, or verbal terms.

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