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    Nondestructive Evaluation for Crack, Corrosion, and Stress Detection
                    for Metal Assemblies and Structures
                       Martin J. Dudziak1, Andre Y. Chervonenkis1, Vladimir Chinarov2
                                                  1
                                                 MODIS Corporation
                                         2
                                          Silicon Dominion Computing, Inc.


                                                       ABSTRACT

Magneto-optic imaging based upon Faraday rotation of polarized light has been successfully applied to the problem of non-
destructive testing of cracks, stress fractures, corrosion, and other surface and subsurface defects in both ferromagnetic and
nonmagnetic metal structures. Some of these applications have been successfully applied to aircraft fuselage and wing
structural examination, as well as to the inspection of tanks and other low-accessibility containers. There are significant
needs and opportunities for improving upon the accuracy, sensitivity, portability, and automation of such non-destructive
evaluation, particularly for aircraft which are by virtue of age, design, or condition subject to dangerous metal fatigue
developments in between scheduled examination. There has been a need for improvements in the basic magneto-optic
sensing technology as well as in the image processing of data gathered from the sensors, and in the refinement of crack and
corrosion recognition algorithms and methods that can enhance automated and assisted recognition. The current research
and development program in non-destructive testing applications at MODIS Corporation has developed several innovations
within these areas that enable wider application of magneto-optic imaging. These include new Fe-Ga based thin-film
technology resulting in (R, Bi) 3(Fe, Ga)5O12 wafers that are demonstrably more sensitive to low-strength magnetic fields.
These films contain (Y, Lu, Bi) 3, (Fe, Ga)5, O12 composition, grown on a transparent single-crystalline substrate of Gd 3 Ga5
O12 composition. Other more sensitive films and substrates have been developed as well. These films have uniaxial
anisotropy due to (111) crystallographic orientation, although with (100) orientation films can be customized for more spatial
resolution and sensitivity due to the almost uniformly planar anisotropy. The MODE (Magneto-Optic Detection and
Encoding) sensor technology is incorporated into a modular scanning apparatus that enables the operation of several modes
of inspection using replaceable video or digital still camera devices as well as variable optics for magnification. Instead of
relying upon traditional eddy current technology for introducing measurable magnetic fields in the sample object being
examined, the MODIS apparatus operates with a high-current (1-5 kA), micro-burst (< 0.5 ms) application to the test surface.
The sensitivity of the MODE Fe-Ga wafers has been demonstrated in laboratory experiments to operate with magnetic fields
that are weaker than those produced by long-duration high-current eddy currents such as are presently being used in NDT
applications. The coupling of higher magneto-optic sensitivity plus a reduction in the eddy current generation and heat
dissipation opens a path to a number of variations and extensions of magneto-optic NDT. Algorithms and software
developed by MODIS and partners for processing and analysis of the scanner output images reside on a Windows 95/NT
computer and are compatible with body-wearable PC systems to enable completely hands-free, mobile inspection and data
collection. The recognition algorithms are based upon standard digital image processing and neural network pattern
recognition that has been successfully applied in other applications.


Keywords: Magneto-optics, sensing, structure, inspection, integrity, materials, defect, stress, non-destructive testing,
wearable PC, pattern recognition, neural network, MODE, SONON, TransPAC




1
 Author contact address: 3413 Hawthorne Avenue, Richmond, VA 23222, (804) 329-8704, mdudziak@silicond.com,
acher@silicond.com, vchinarov@silicond.com
1. INTRODUCTION

Through the employment of new magneto-optic sensitive materials and improved image resolution algorithms based upon
neural-network-like pattern recognition techniques it is possible to attain increased resolution and detail of imaging for the
inspection of cracks, corrosion, and stress features in a variety of metal assemblies. This approach lends itself to engineering
systems and applications offering greater portability and versatility than many alternative non-destructive testing methods
including prior magneto-optic imaging. The present level of research and development activity has concentrated upon the
development of three foundational components for an advanced architecture of nondestructive testing and imaging, namely:

   the refinement and production of Fe-Ga based thin-film sensors,
   the refinement and testing of the SONON network algorithms, to provide more accurate M-O imaging, and
   the integration of sensors and recognition software into a portable, wearable PC platform that enables inspector linkage
    via wireless modem to CAD, CAE, and GIS server and database resources.

The use of algorithms and software drawn from image processing and object recognition applications has a dual function.
First it enables improvement of image quality for real-time onsite inspection and evaluation of data collected by an inspector
using portable equipment, with or without direct real-time communication with expert engineering or scientific staff. Second
it affords a means to tailor certain image collection parameters including application of electromagnetic enhancement fields
applied by eddy current or permanent magnets, in the vicinity of the imaging apparatus. The ultimate purpose is to enable
faster, simpler, more accurate, and more economical means of performing nondestructive inspection, and doing so requires
making changes to a system design that will more easily accommodate use of standard commercial computing components as
well as non-specialist data collectors and inspectors. Each of these component activities is reviewed in the following
sections.

                          2.   MODE™ MAGNETO-OPTIC SENSING AND IMAGING

Magneto-optic imaging and sensing for non-destructive testing and evaluation has been studied and implemented widely over
the last decade in particular. A number of applications have been demonstrated including aircraft structural assembly
inspection and examination of pipes and tanks for corrosion. (3-6, 8, 11) The field of magneto-optic materials is hardly new and
Fe-Ga substrates have been studied since the 1970’s. (1,2,7,10) Eddy current application has been the dominant source of
magnetization for sample surfaces. (7,8)

Silicon Dominion has been working in a partnered research and development program with MODIS Corporation, developers
of the MODE magneto-optic detection and encoding technology. This is based upon a field visualizing film (FVF) which
consists of a transparent ferromagnetic layer of Bi-substituted iron-garnet grown by LPE technique on a non-magnetic
substrate. (1,2,10) The FVF chemistry is characterized by the formula (R Bi) 3 (M Fe)5O12. The value for R can be one of several
rare-earth ions (Y, Lu, Tm, Gd, Ho, Dy, Tb, Eu for example). The variable M is generally Ga or Al. Magnetic and magneto-
optic properties of the FVF are determined by composition, growth conditions and post-epitaxial treatment. The specific
Faraday rotation of 1.5-2.0 deg/µm and an absorption coefficient less than 0.4 dB/µ are available in a generic composition
(Tm Bi)3 (Fe Ga)5O12. Uniaxial anisotropy ranges from 10-20 kOe with corecivity of 0.1 Oe. High contrast domain
structures can be easily observed using a polarizing microscope. Figures 1, 2 and 3 illustrate sample images obtained with
the MODE technology, all laboratory images made in ambient environments using sample materials (steel plates with defects
(1,2) and microprocessor chip circuitry pads (3)) such as may be encountered on aircraft, aerospace vehicles and pipe or tank
assemblies.

The magneto-optic layer or FVF is created by growing the epitaxial layer on the garnet substrate, deposited in a flux
containing a solvent of composition Bi 2O3-PbO-B2O3 as well as garnet-formed oxides at a temperature range of 940K to
1108K. By introducing a high level of Bi 3+ ion substitution into the FVF a high MO figure of merit can be achieved, such
that Ψ= 2ΘF / α > 10 grad/dB. An important feature of the FVF of value for magnetic anomaly and variation studies,
particularly where mechanical speed in scanning the sample may be required, is the high domain wall velocity (> 1000m/s)
obtained in four types of films: (i) high-anisotropic-oriented films with Y and Lu composition, in the presence only of in-
plane magnetic fields, (ii) films with Gd and Tm, with angular momentum compensation (AMC), (iii) films with Y, Lu, and
Pr (orthorhombical magnetic anisotropy (ORMA), and (iv) films with Gd and Eu (both AMC and ORMA).
The images of defects in steel plates such as are shown in Figures 1, 2, and 3 illustrate the refinement of the MODE thin film.
In Figure 1 the plate is approximately 1.5 mm uniform thickness and the defects approximately 0.1mm to 0.2mm in depth.
The longitudinal scratch (upper side of plate, shown in the far right (optical) image) is < 0.1mm depth. The defects on the
lower side (shown in the middle (optical) image are, from left to right: (a) 2mm length, 0.1mm max. width; (b) 0.2mm max.
depth; and (c) 0.6mm length, 0.2mm width, 0.1mm max. depth. Typically the saturation magnetization is approx. 10 kG and
for imaging without an applied eddy current an in-plane external magnetic field is applied with saturation @ 1.0 – 1.5 kOe.
By being able to image clearly defects originating on either side or inside the sample in one image, along with optically
sensitive features, the composite image affords the NDT operator or an expert system the capability to make use of additional
information pertaining to relative alignment and position of defects and critical other structural features.

Figure 2 illustrates imaging of microcracks (left) and impurity defects (right) in ordinary steel plates of approx. 2 mm
thickness. These were obtained also without an eddy current as described above. It is for the matching and identification
process following the collection of such images that the SONON algorithms described in Section 3 are being applied.




                Figure 1          MODE™ Imaging steel plate by magneto-optics(left)
                                   and ordinary light (middle and right)




Figure 2       MODE™ imaging of steel with microcracks(left) and impurity defect (right)

The circuit bonding pads shown in Figure 3 are in the internal layer of a standard smart card and are beneath a plastic and
clear laminate layer. In all cases of images shown in this study the distance from the sensor to the sample surface < 0.75mm.
It is suggested that individual smart cards and other circuits can be uniquely identified by this imaging techniques due to the
unique signature or “fingerprint” of even standard chip packaging and circuit board techniques. However, these novel
applications depend upon there being an effective and rapid means of performing both the image capture and the analysis.
Figure 3          Magneto-optic imaging of 16-bit microprocessor lead pads

Figure 4 provides a schematic of the basic operation of magneto-optic imaging using a MODE thin film crystal sensor. By
incorporating the polarized light source into a fiber optic delivery system, the packaging of a sensor unit can be sized down to
a chip set incorporating CCD and control logic in one device and optics in a second hybrid device. Video output is captured
by a Winnov VIDEUM board and transferred by software into either .AVI files for video streams or into .JPG files for single-
frame images. Immediately following, Figure 5 illustrates saturation magnetization properties of the MODE film [B(G)] and
an iron platelet [B(Fe)] - the ratio of the anisotropy field H / B(G) increases over the normal distance z.




                              Figure    4    Basic operation of MODE™ Imaging
                                  1.    sample         2. base
                                  3.    sensor         4. lens
                                  5.    lens           6. polarizing film
                                  7.    camera         8. pulse current source


In the case of the MODE sensor, there are only modest variations in image features when there is some difference in the
distance from the sensor surface to the sample. However, for non-flat surfaces there is an alternative approach to modifying
the entire scanner apparatus. A flexible plasticine tape with embedded magnetizable particles is laid upon the convex,
concave, or otherwise non-flat surface and a 10-30 kA current is applied to the sample for a duration of 10-20 ms. This has
the effect of creating a magnetization of the tape compound that is aligned with the domain structure of the sample. The tape
is removed and prepared for imaging with a conventional MODE scanner as if it were a flat steel plate or other sample on a
workbench. Figure 6 illustrates the method of conducting this imprint operation and Figure 7 shows result of such an image
taken of a magnetic tape segment that had been applied to a nonflat copper plate approx., 0.5mm thick with defects on its
undersurface.
Figure 5         MODE™ Saturation Magnetization Levels




                Figure 6    Basic operation of MODE™ magnetic tape imaging
          1. sample   2. defects 8. pulsed current source       9. magnetic tape




                       Figure 7          MODE™ image of magnetic tape after test


                                3. THE SONON RECOGNITION ALGORITHM

For enhancement and characterization of crack and defect features within the type of grayscale images collected by the
MODE scanner, a neural-like algorithm has been refined and is being tested for usefulness because of its resilience
mathematically to working with noisy and incomplete data. The SONON (Self-Organizing Non-equilibrium Oscillator
Network) algorithm and resulting software is based upon a neural-like network model of a content-addressable memory that
exploits the dynamics of coupled overdamped oscillators moving in a double-well potential. (12,13,14) Coupling coefficients
characterize pair-wise nature of interactions between network elements with all-to-all connections. The fundamental dynamic
equation is given by
                                                  d           ∂H
                                                     x (t ) = −  .            (1)
                                                  dt           ∂x

The model accounts for the connectivity of all elements of the network, with a free energy functional, H, containing the
homogeneous terms representing cubic forces acting on each element, H , and the interaction H int , terms, respectively

                                                      1 N 2
                                             H =−       ∑ xi ( 2 − xi2 ),
                                                      4 i =1
                                                                                     (2)

and
                                                         1 N
                                             H int = −     ∑wij x j x i .
                                                         2 i , j =1
                                                                                     (3)


The network is composed of N coupled bistable elements that may be considered as neural-like network activities. Each
element is an overdamped non-linear oscillator moving in a double-well potential H , pair-wise interactions between all
elements are given by Eq. (3). The network has the gradient dynamics with all limit configurations (these may be considered
as patterns to be learned) contained within the set of fixed point attractors. For a given coupling matrix wij , the network
evolves towards such limit configurations starting from any initial input configurations of bistable elements (the elements are
distributed among left and right wells of the potential with negative and positive values, respectively). The basic updating
scheme for learning and training is given by

                               wij ( k + 1) = wij ( k ) + η∑ε r ( L−1 ) ri x j ( k + 1).       (4)
                                                            r


where k is the iteration step, parameter η determines the rate of learning, and matrix L is defined as

                                             Lik = δ ik ( 3x k2 − 1) − wik ,         (5)

This updating algorithm will be used for the network learning as well as for retrieving the stored memories when applied
patterns are just corrupted memorized ones. The actual values of elements in all the patterns are not the bipolar (-1 or +1)
ones, but they are real values established in the network when it reaches its final state. These values are stable states that
correspond to the minima of the double-well potentials for each oscillator. It should be underlined here, that fixed-point
attractors in our case do not coincide, like in all Hopfield-type networks, with the corners of a hypercube,. The iteration
learning procedure is constructed in such a way that applied patterns repeatedly presented one by one, but the next is
presented only after the weight coefficients are adjusted according to the learning rule. The learning procedure lasts until
MSE criterion ε will be less or equal some given small value. In all our simulations the obtained matrix practically coincides
                         constructed from the key patterns ξ0 µ. We should underline here that in the coupling matrix
                 0
with the matrix wij
constructed so far, all diagonal matrix elements wii are nonzero values.

In Figure 8 is shown the dependence of MSE criterion ε on the number of iterations needed to learn, for a network with N=20
elements, the coupling matrix Wij . In Figure 9 is given the dependence of the sum of all matrix elements on the number of
iterations for the network with N=20 units when only first pattern ξ1 is used to learn the network. Both dependencies
characterize the rate of convergence process during the learning phase and point to an efficiency that significantly exceeds
many classical Hopfield-type as well as feed-forward pattern classifiers, indicating a real-time potential for operating on
image feature data, extracted by conventional DCT and wavelet techniques, that will run adequately on a platform such as
currently available Pentium-based wearable PCs, as used in the TransPAC design (cf. Section 4).
2.5



                              2.0



                              1.5
                      MSE




                              1.0



                              0.5



                              0.0


                                       0       2   4       6        8        10        12       14
                                                   Number of iteration (*100)

     Figure 8        Dependence of MSE on number of iterations needed to learn coupling
                           matrix Wij for a network with N=20 elements



                              6



                              4
                      Sum W




                              2



                              0



                              -2



                              -4


                                   0       2       4       6        8         10        12        14

                                                   Number of iteration (* 100)

     Figure 9 Rate of convergence of the learning phase.                            Dependence of sum of all
    matrix elements ∑ ij
                     W                     on number of iterations for the network with N=20 units
                                   i, j
The results presented in this paper and others () concern the computational possibilities of a network consisting of coupled
bistable units that may store many more memory patterns in comparison with Hopfield-type neural networks. These new
possibilities may be realized due to the proposed learning algorithm that may induce the system to learn efficiently. Using
known patterns with up to 45%- 50% of distortions, the coupling matrix may be fully reconstructed. In some sense, the
developed technique resembles a reconstruction of the dynamical system using its attractors. For example, a network
composed of N coupled bistable units for a fixed coupling matrix has several stable fixed-point-like attractors that are
associated with the memorized patterns. If these patterns and the coupling matrix are known, the applied patterns taken as
the initial values for the dynamical system may be restored in few iterations. If some applied patterns belong to another set
(e.g., they were obtained as a fixed-point attractors for different coupling matrix), they would be easily recognized giving
another resulting coupling matrix that is updated during the retrieval phase. Therefore, the identification of memories
(attractors) could be easily done. It was shown in simulations () that applied patterns with 45% of distortions may be
effectively restored. If only memorized patterns are known the coupling matrix will be reconstructed after several iterations.
In both cases the updating procedure for the coupling matrix uses the minimization of the least-mean-squares errors between
the applied and desired patterns.

From a computational point of view the proposed network offers definite advantages in comparison with the traditional
Hopfield-type networks. It has good performance, it may learn efficiently, and has bigger memory capacity. In examples
described above we have seen that the network with N=8 elements may store seven stable patterns that may be perfectly
retrieved even when half of its elements are distorted by inversion of their signs. It should be said also that the performance
of this learning algorithm depends on a judicious choice of the rule parameter η. It is worthy to underline that the network
may operate also in a noisy environment, and for this reason it is useful for the MODE-based imaging. Recognition of linear,
angular, and area features indicative of magnetic variations that are themselves indicatorsof stress, corrosion, or cracking in a
metallic sample are intensely subject to confusion due to noise introduced by movements of the scanner and by microscopic
distortions in the placement of the scanner at the time of image frame capture. It is necessary to compare temporally adjacent
images for comparison as well as to compare detected features against a template library of learned feature types and the
SONON algorithm can provide a tool for this task.

                                   4. THE TransPAC™ MOBILE NDT SYSTEM

Notwithstanding superior magneto-optics and image recognition, there is a further need to be able to perform many imaging
tasks in diverse physical environments, locations, timings, and with more ease of use than afforded by existing alternatives.
The TransPAC system was designed in order to provide a field-ready, robust computer platform capable of handling one or
more types of video-based scanners including the MagVision and commercial variants currently being implemented.
TransPAC is illustrated by Figure 10 which shows the operational scheme and organization of components. At the heart is a
standard wearable personal computer running Windows 95/98 and capable of being worn on the body or in a backpack or
beltpack. Several commercial models are available (Mentis, Via-II, Xybernaut) and the prototype TransPAC is being
designed to accommodate more than one vendor’s product line in keeping with a philosophy of platform and product
independence. The Mentis model (hardware produced by Interactive Solutions, Inc.) was selected for its physical ruggedness
and hardware expandability. Aside from the NDT/NDI applications, the TransPAC is very much of a conventional portable
PC, offering much the same as a notebook PC in capabilities, for data collection or other types of field work but with speech
and smart card security options built into the design (cf. Section 4.3). For NDT/NDI there are two additional components –
the MagVision NDT Scanner set and the MagVision NDT Tools software application.

4.1 MagVision NDT Scanner
This set of two hardware plug-in modules consists of a sensor and video capture module which has a changeable scanner unit
similar to that illustrated in Figure 11 below, and a pulsed current generator module. The scanner module enables the user to
change the actual sensor wafer element in order to afford either optical and magnetic imaging or only magnetic imaging, to
modify the size of the sensor and the magnification of the video image, and to modify the strength of an external magentic
field if one is used for nonmagnetic and non-current-driven applications. The objective of the multiplicity of scanner features
is to provide versatility for the end user. One TransPAC system with several attachments can serve for many different jobs in
the field and enables the technician to try different techniques on the same sample while still at the inspection site. The
pulsed current module serves to provide a variable amplitude and variable duration current pulse that is applied to
nonmagnetic surfaces being imaged. It’s power supply is independent from the TransPAC while the control is driven by the
user through the PC using a handheld infrared control. This affords the benefit of synchronous PC-centered control of the
generator and current application while maintained electrical separation of the devices for safety and electronics sensitivity
considerations.

4.2 MagVision NDT Tools
MagVision NDT Tools is a Windows 95/98 application that provides complete test event logging with image processing
capabilities and a built-in database from which records and tables can be rapidly uploaded to a server or another PC on a
LAN or by modem after work completion. Figure 12 provides an illustration of the Verite image comparison module that
enables a user to rapidly compare visually and with onboard automatic comparison the features of an image just taken with
the TransPAC and one that is from a previous test or else a master template used to help determine both defect features in the
sample being imaged and also calibration of the scanner system.
CRT or                                                      Beltpack or
                                    LCD                                                        Bodypack
                                   Display                                                      Carrying
                                                                                                  Unit
            Microphone


                                                                Base System                         AC
                                                                   Unit                            Power
                     Headphone
                                                                                                   Adapter
                     s


                                                              Extension Pack
                                                                                                    Kbd / Mouse
                                           CD/DVD/Tape
                                           Unit


                                                               Battery Pack
                                                                                                Wireless
                     Cell Phone                                                                 Modem




                          RS232 &                       Video Input                    PCMCIA
                           Parallel                      Device(s)                     Data Acq
                         Acquisition                   (MagVision)                     Device(s)


                                   Figure 10 TransPAC™ System Components


The operator has the capability of viewing a maximum of four separate images that can derive from either the active scanner,
disk file, or internet sources. Any one image can be compared with another by using a variety of user-configurable
algorithms built in to the application – edge enhancement, area texture analysis, Fourier, Gabor, wavelet, and neural network
tools are available for use with the image as a whole or for a user-selected rectangular region. The primary use of this tool is
to enable the operator to rapidly isolate and identify interesting features and to bring out highlights in images while the NDI
operation is ongoing. With additional features, described in Section 4.3, the user can maximize the opportunity to investigate
other regions of the observed structure, whether the system is (as at present) purely under manual control and manipulation or
being run by an autonomous agent as in a surface crawling robot.
Figure 11 TransPAC with MagVision scanner unit




                           Figure 12 Verite™ Image Comparator Application

4.3 Speech, Security, CADD, and Online Communications
Most wearable personal computers have the capability for a keyboard interface and also a pen-based input. This may suffice
for many conventional data collection tasks. However, to make the imposition that an NDT/NDI technician operating in
potentially adverse and dangerous conditions outdoors and with the concern for correct placement of the MODE scanner and
the pulse current generator must use a handheld type of keyboard or tablet is inappropriate given the alternatives. With
recent and current in-the-field magneto-optic and ultrasonic NDT equipment, more extensive positioning and arranging has
been necessary, mitigating the issue of rapid hands-free command operation and repetitive sequencing or images, but with the
compactness of the MagVision components, as low as 3 in. by 3 in. and under 8 oz. weight, less cable, it becomes desirable
to have as compact and easy to use a field computer as possible.

TransPAC uses a complete speech-to-text-to-database command interface that supplements rather than replaces the
pen/keyboard/mouse channel. This speech interface provides for a trained vocabulary of approximately 100 words that are
speaker-independent and resilient to external noise and in particular speaker accent, tone, and volume variations and also
non-verbal noise such as that from operating machinery. The software is used within a widely-accepted transportation data
2
collection product for highway and urban roadside asset data collection            and has demonstrated the rigors of tests with
variable speakers and noise levels.

The voice stream along with other sensor data including an optional laser range finder, GPS, and digital camera is input along
with the video data stream from the MagVision scanner module into a data recording application that organizes the respective
elements into a record structure. This record structure undergoes an automatic quality assurance test which can optionally
include the audio feedback, through headset earphones, of all speech input and all record field data for operator approval.
Once manually or automatically approved, the record data including NDT images and any on-site real-time interpretation is
output into an Access database for future use including direct uploading to a server.

The roles of the GPS and laser range finder depend upon the NDT application. For certain outdoor inspection tasks (aircraft,
tanks, pipelines, ships, bridges, highway poles, transmission towers) it may be necessary to reference the location of the test
and the artifact/structure being imaged. A variety of GPS units with as much as sub-meter accuracy may be employed with
TransPAC. One such system is the Trimble Pro XRS 1m real-time or post-process 12-channel GPS/DGPS receiver and
antenna which is typically worn by the operator in a convenient backpack with no interference to physical movement or the
operation of the TransPAC and the MagVision modules.

The TransPAC display capability includes three options – a standard flat-panel screen that can be worn with a harness
allowing full frontal large-scale viewing during operation, a flat-panel screen with flexible hose attachments that enables the
display unit to be placed in a convenient location on a vertical or horizontal pile or strut, and a headset eyepiece display
capable of the same full 800x600 resolution as the flat-panel displays. The former two approaches require a VGA cable
running from the main TransPAC computer whereas the headset unit has a cable for video and two-way audio that will not
interfere with operator hand or foot mobility.

The role of the 16-bit 16K microprocessor smart card within TransPAC is twofold. First it serves as a compact and reliable
form of access security for the system, identifying the operator and thereby setting up all access parameters for online
network or internet linkages while the TransPAC is being used on an inspection assignment. The issue of security and
traceability is of paramount importance from the larger-scale systems engineering and business process perspective in that a
widely-deployed, operator-intensive NDT/NDI activity puts more weight and responsibility on the persons doing the tests
and demands more accountability than activities which heretofore may have depended upon special planning and a special
team of experts. As the operation of MODE-based NDT/NDI becomes more ubiquitous, the risks of human organizational
error increase and this form of security, already built into TransPAC for other applications, 3 is an apt response. Currently the
TransPAC has an industry-standard PCMCIA Type II interface for the smart card device. The card remains in the unit during
all times of operation.

                                                      5. CONCLUSION

A prototype system for inspection of metal fatigue and defects has been designed and constructed for field testing on aircraft,
tanks, pipes, and bridges. A neural-like algorithm demonstrates progress toward the identification of image regions requiring
enhancement due to noise introduced by movement or irregularities in the physical imaging process, and the same algorithm
and software demonstrates improvements in automated detection of critical features that may be missed by a human observer
conducting real-time inspection and analysis. The MODE magneto-optic sensor performs robustly in a variety of physical
environments including the presence of layers of dirt, ice, and other non-homogeneous thin layers over the surface of the
scanned sample. By use of a compact yet desktop-compatible PC as an imaging platform, the apparatus is useable in both
mobile and robotic (9) applications. Further research is being focused upon the refinement and validation of the recognition
software in order to provide additional semi-automated image recognition capabilities to the system.




2
    VoCarta by Datria Systems, Inc. , Englewood, CO
3
    primarily in health care (bedside and home visits), automotive service and inspection, and inventory control
6. ACKNOWLEDGEMENTS

This work was supported jointly by internal funding from Silicon Dominion Computing, Inc. of Richmond, Virginia, and
MODIS Corporation of Reston, Virginia.

                                                   7. REFERENCES

1. Chervonenkis A. Ya. & Randoshkin V.V., Applied Magnetooptics, Energoatomizdat, Moscow, 1990 (in Russian)

2. Chervonenkis, A. Ya., “Magneto-optic visualization of spatial inhomogenous magnetic fields”, Proc. ISMO, Kharkov,
Russia, 1991, 10-34

3. Fitzpatrick G. L., “Novel eddy current field modulation if magneto-optic films for real time imaging of fatigue cracks and
hidden corrosion”, SPIE Proceedings, Vol. 2001, 210-222, 1993.

4. Fitzpatrick, G. L., Thome, D. K., Skaugset, R. L., Shih, E. Y., Shih, W. C., "Novel Eddy Current Field Modulations of
Magneto-optic Garnet Films for Real-Time Imaging of Fatigue Cracks and Hidden Corrosion," The International Society for
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5. Fitzpatrick, G. L., Thome, D.K., Skaugset, R. L., Shih, W. C., "Magneto-Optic/Eddy Current Imaging of Subsurface
Corrosion and Fatigue Cracks in Aging Aircraft”, in Review of Progress in Quantitative Nondestructive Evaluation, Vol. 15,
edited by D.O. Thompson and D.E. Chimenti, Plenum Press, NY, 1996.

6. Fitzpatrick, G. L., Thome, D. K., Skaugset, R. L., Shih, W. C., "Detection of Cracks Under Cladding Using Magneto-Optic
Imaging and Rotating In-plane Magnetization”, The International Society for Optical Engineering - SPIE Proceedings,
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7. Dudziak, M. J. & Chervonenkis, A. Ya., “A Family of Microinstruments for Smart Materials, Energy Management, and
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8. Davis, C. W., Fulton, J. P., Nath, S., and Namkung, M., “Combined Investigation of Eddy Current and Ultrasonic
Techniques for Composite Materials NDE”, Review of Progress in Quantitative Nondestructive Evaluation, Vol. 14B,
Snowmass, Colorado, July 1994, pp. 1295-1301

9. Lozev, M. G., MacLaurin, C. C., Butts, M. L., and Inigo, R. M., “Prototype Crawling Robotics System for Remote Visual
Inspection of High-Mast Light Poles”, Virginia Transportation Research Council, Report FHWA/VTRC 98R2, July 1997

10. A. Chervonenkis and M. Dudziak, 1998, “High Sensitivity Magneto-Optic Devices for Weak Magnetic Field
Measurements and Localization”, 2nd Magneto-Optics Conference and Workshop, Moscow State University (preprint
available 10/98)

11. M. Dudziak and A. Chervonenkis 1998, “Structural Integrity Inspection and Monitoring Using Magneto-Optic Sensors”,
SPIE 1998 Symposium on Intelligent Systems and Advanced Manufacturing, 11/98 (preprint available 11/98)

12. V. Chinarov and T. Gergely 1997, “Non-equilibrium dynamics and synchronization in ensembles of interacting neural
nets”, AeroScience 97, Orlando, FL

13. V. Chinarov and T. Gergely 1998, “Patterns of Synchronous and Asynchronous Behavior in Heterogenous Active
Networks”, Massively Parallel Computing Systems 98, Colorado Springs, CO

14. V. Chinarov 1998, “Modelling self-organization processes in non-equilibrium neural networks”, SAMS, 30, 311-329

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Ndemetalassemb

  • 1. header for SPIE use Nondestructive Evaluation for Crack, Corrosion, and Stress Detection for Metal Assemblies and Structures Martin J. Dudziak1, Andre Y. Chervonenkis1, Vladimir Chinarov2 1 MODIS Corporation 2 Silicon Dominion Computing, Inc. ABSTRACT Magneto-optic imaging based upon Faraday rotation of polarized light has been successfully applied to the problem of non- destructive testing of cracks, stress fractures, corrosion, and other surface and subsurface defects in both ferromagnetic and nonmagnetic metal structures. Some of these applications have been successfully applied to aircraft fuselage and wing structural examination, as well as to the inspection of tanks and other low-accessibility containers. There are significant needs and opportunities for improving upon the accuracy, sensitivity, portability, and automation of such non-destructive evaluation, particularly for aircraft which are by virtue of age, design, or condition subject to dangerous metal fatigue developments in between scheduled examination. There has been a need for improvements in the basic magneto-optic sensing technology as well as in the image processing of data gathered from the sensors, and in the refinement of crack and corrosion recognition algorithms and methods that can enhance automated and assisted recognition. The current research and development program in non-destructive testing applications at MODIS Corporation has developed several innovations within these areas that enable wider application of magneto-optic imaging. These include new Fe-Ga based thin-film technology resulting in (R, Bi) 3(Fe, Ga)5O12 wafers that are demonstrably more sensitive to low-strength magnetic fields. These films contain (Y, Lu, Bi) 3, (Fe, Ga)5, O12 composition, grown on a transparent single-crystalline substrate of Gd 3 Ga5 O12 composition. Other more sensitive films and substrates have been developed as well. These films have uniaxial anisotropy due to (111) crystallographic orientation, although with (100) orientation films can be customized for more spatial resolution and sensitivity due to the almost uniformly planar anisotropy. The MODE (Magneto-Optic Detection and Encoding) sensor technology is incorporated into a modular scanning apparatus that enables the operation of several modes of inspection using replaceable video or digital still camera devices as well as variable optics for magnification. Instead of relying upon traditional eddy current technology for introducing measurable magnetic fields in the sample object being examined, the MODIS apparatus operates with a high-current (1-5 kA), micro-burst (< 0.5 ms) application to the test surface. The sensitivity of the MODE Fe-Ga wafers has been demonstrated in laboratory experiments to operate with magnetic fields that are weaker than those produced by long-duration high-current eddy currents such as are presently being used in NDT applications. The coupling of higher magneto-optic sensitivity plus a reduction in the eddy current generation and heat dissipation opens a path to a number of variations and extensions of magneto-optic NDT. Algorithms and software developed by MODIS and partners for processing and analysis of the scanner output images reside on a Windows 95/NT computer and are compatible with body-wearable PC systems to enable completely hands-free, mobile inspection and data collection. The recognition algorithms are based upon standard digital image processing and neural network pattern recognition that has been successfully applied in other applications. Keywords: Magneto-optics, sensing, structure, inspection, integrity, materials, defect, stress, non-destructive testing, wearable PC, pattern recognition, neural network, MODE, SONON, TransPAC 1 Author contact address: 3413 Hawthorne Avenue, Richmond, VA 23222, (804) 329-8704, mdudziak@silicond.com, acher@silicond.com, vchinarov@silicond.com
  • 2. 1. INTRODUCTION Through the employment of new magneto-optic sensitive materials and improved image resolution algorithms based upon neural-network-like pattern recognition techniques it is possible to attain increased resolution and detail of imaging for the inspection of cracks, corrosion, and stress features in a variety of metal assemblies. This approach lends itself to engineering systems and applications offering greater portability and versatility than many alternative non-destructive testing methods including prior magneto-optic imaging. The present level of research and development activity has concentrated upon the development of three foundational components for an advanced architecture of nondestructive testing and imaging, namely:  the refinement and production of Fe-Ga based thin-film sensors,  the refinement and testing of the SONON network algorithms, to provide more accurate M-O imaging, and  the integration of sensors and recognition software into a portable, wearable PC platform that enables inspector linkage via wireless modem to CAD, CAE, and GIS server and database resources. The use of algorithms and software drawn from image processing and object recognition applications has a dual function. First it enables improvement of image quality for real-time onsite inspection and evaluation of data collected by an inspector using portable equipment, with or without direct real-time communication with expert engineering or scientific staff. Second it affords a means to tailor certain image collection parameters including application of electromagnetic enhancement fields applied by eddy current or permanent magnets, in the vicinity of the imaging apparatus. The ultimate purpose is to enable faster, simpler, more accurate, and more economical means of performing nondestructive inspection, and doing so requires making changes to a system design that will more easily accommodate use of standard commercial computing components as well as non-specialist data collectors and inspectors. Each of these component activities is reviewed in the following sections. 2. MODE™ MAGNETO-OPTIC SENSING AND IMAGING Magneto-optic imaging and sensing for non-destructive testing and evaluation has been studied and implemented widely over the last decade in particular. A number of applications have been demonstrated including aircraft structural assembly inspection and examination of pipes and tanks for corrosion. (3-6, 8, 11) The field of magneto-optic materials is hardly new and Fe-Ga substrates have been studied since the 1970’s. (1,2,7,10) Eddy current application has been the dominant source of magnetization for sample surfaces. (7,8) Silicon Dominion has been working in a partnered research and development program with MODIS Corporation, developers of the MODE magneto-optic detection and encoding technology. This is based upon a field visualizing film (FVF) which consists of a transparent ferromagnetic layer of Bi-substituted iron-garnet grown by LPE technique on a non-magnetic substrate. (1,2,10) The FVF chemistry is characterized by the formula (R Bi) 3 (M Fe)5O12. The value for R can be one of several rare-earth ions (Y, Lu, Tm, Gd, Ho, Dy, Tb, Eu for example). The variable M is generally Ga or Al. Magnetic and magneto- optic properties of the FVF are determined by composition, growth conditions and post-epitaxial treatment. The specific Faraday rotation of 1.5-2.0 deg/µm and an absorption coefficient less than 0.4 dB/µ are available in a generic composition (Tm Bi)3 (Fe Ga)5O12. Uniaxial anisotropy ranges from 10-20 kOe with corecivity of 0.1 Oe. High contrast domain structures can be easily observed using a polarizing microscope. Figures 1, 2 and 3 illustrate sample images obtained with the MODE technology, all laboratory images made in ambient environments using sample materials (steel plates with defects (1,2) and microprocessor chip circuitry pads (3)) such as may be encountered on aircraft, aerospace vehicles and pipe or tank assemblies. The magneto-optic layer or FVF is created by growing the epitaxial layer on the garnet substrate, deposited in a flux containing a solvent of composition Bi 2O3-PbO-B2O3 as well as garnet-formed oxides at a temperature range of 940K to 1108K. By introducing a high level of Bi 3+ ion substitution into the FVF a high MO figure of merit can be achieved, such that Ψ= 2ΘF / α > 10 grad/dB. An important feature of the FVF of value for magnetic anomaly and variation studies, particularly where mechanical speed in scanning the sample may be required, is the high domain wall velocity (> 1000m/s) obtained in four types of films: (i) high-anisotropic-oriented films with Y and Lu composition, in the presence only of in- plane magnetic fields, (ii) films with Gd and Tm, with angular momentum compensation (AMC), (iii) films with Y, Lu, and Pr (orthorhombical magnetic anisotropy (ORMA), and (iv) films with Gd and Eu (both AMC and ORMA).
  • 3. The images of defects in steel plates such as are shown in Figures 1, 2, and 3 illustrate the refinement of the MODE thin film. In Figure 1 the plate is approximately 1.5 mm uniform thickness and the defects approximately 0.1mm to 0.2mm in depth. The longitudinal scratch (upper side of plate, shown in the far right (optical) image) is < 0.1mm depth. The defects on the lower side (shown in the middle (optical) image are, from left to right: (a) 2mm length, 0.1mm max. width; (b) 0.2mm max. depth; and (c) 0.6mm length, 0.2mm width, 0.1mm max. depth. Typically the saturation magnetization is approx. 10 kG and for imaging without an applied eddy current an in-plane external magnetic field is applied with saturation @ 1.0 – 1.5 kOe. By being able to image clearly defects originating on either side or inside the sample in one image, along with optically sensitive features, the composite image affords the NDT operator or an expert system the capability to make use of additional information pertaining to relative alignment and position of defects and critical other structural features. Figure 2 illustrates imaging of microcracks (left) and impurity defects (right) in ordinary steel plates of approx. 2 mm thickness. These were obtained also without an eddy current as described above. It is for the matching and identification process following the collection of such images that the SONON algorithms described in Section 3 are being applied. Figure 1 MODE™ Imaging steel plate by magneto-optics(left) and ordinary light (middle and right) Figure 2 MODE™ imaging of steel with microcracks(left) and impurity defect (right) The circuit bonding pads shown in Figure 3 are in the internal layer of a standard smart card and are beneath a plastic and clear laminate layer. In all cases of images shown in this study the distance from the sensor to the sample surface < 0.75mm. It is suggested that individual smart cards and other circuits can be uniquely identified by this imaging techniques due to the unique signature or “fingerprint” of even standard chip packaging and circuit board techniques. However, these novel applications depend upon there being an effective and rapid means of performing both the image capture and the analysis.
  • 4. Figure 3 Magneto-optic imaging of 16-bit microprocessor lead pads Figure 4 provides a schematic of the basic operation of magneto-optic imaging using a MODE thin film crystal sensor. By incorporating the polarized light source into a fiber optic delivery system, the packaging of a sensor unit can be sized down to a chip set incorporating CCD and control logic in one device and optics in a second hybrid device. Video output is captured by a Winnov VIDEUM board and transferred by software into either .AVI files for video streams or into .JPG files for single- frame images. Immediately following, Figure 5 illustrates saturation magnetization properties of the MODE film [B(G)] and an iron platelet [B(Fe)] - the ratio of the anisotropy field H / B(G) increases over the normal distance z. Figure 4 Basic operation of MODE™ Imaging 1. sample 2. base 3. sensor 4. lens 5. lens 6. polarizing film 7. camera 8. pulse current source In the case of the MODE sensor, there are only modest variations in image features when there is some difference in the distance from the sensor surface to the sample. However, for non-flat surfaces there is an alternative approach to modifying the entire scanner apparatus. A flexible plasticine tape with embedded magnetizable particles is laid upon the convex, concave, or otherwise non-flat surface and a 10-30 kA current is applied to the sample for a duration of 10-20 ms. This has the effect of creating a magnetization of the tape compound that is aligned with the domain structure of the sample. The tape is removed and prepared for imaging with a conventional MODE scanner as if it were a flat steel plate or other sample on a workbench. Figure 6 illustrates the method of conducting this imprint operation and Figure 7 shows result of such an image taken of a magnetic tape segment that had been applied to a nonflat copper plate approx., 0.5mm thick with defects on its undersurface.
  • 5. Figure 5 MODE™ Saturation Magnetization Levels Figure 6 Basic operation of MODE™ magnetic tape imaging 1. sample 2. defects 8. pulsed current source 9. magnetic tape Figure 7 MODE™ image of magnetic tape after test 3. THE SONON RECOGNITION ALGORITHM For enhancement and characterization of crack and defect features within the type of grayscale images collected by the MODE scanner, a neural-like algorithm has been refined and is being tested for usefulness because of its resilience mathematically to working with noisy and incomplete data. The SONON (Self-Organizing Non-equilibrium Oscillator Network) algorithm and resulting software is based upon a neural-like network model of a content-addressable memory that exploits the dynamics of coupled overdamped oscillators moving in a double-well potential. (12,13,14) Coupling coefficients
  • 6. characterize pair-wise nature of interactions between network elements with all-to-all connections. The fundamental dynamic equation is given by d  ∂H x (t ) = −  . (1) dt ∂x The model accounts for the connectivity of all elements of the network, with a free energy functional, H, containing the homogeneous terms representing cubic forces acting on each element, H , and the interaction H int , terms, respectively 1 N 2 H =− ∑ xi ( 2 − xi2 ), 4 i =1 (2) and 1 N H int = − ∑wij x j x i . 2 i , j =1 (3) The network is composed of N coupled bistable elements that may be considered as neural-like network activities. Each element is an overdamped non-linear oscillator moving in a double-well potential H , pair-wise interactions between all elements are given by Eq. (3). The network has the gradient dynamics with all limit configurations (these may be considered as patterns to be learned) contained within the set of fixed point attractors. For a given coupling matrix wij , the network evolves towards such limit configurations starting from any initial input configurations of bistable elements (the elements are distributed among left and right wells of the potential with negative and positive values, respectively). The basic updating scheme for learning and training is given by wij ( k + 1) = wij ( k ) + η∑ε r ( L−1 ) ri x j ( k + 1). (4) r where k is the iteration step, parameter η determines the rate of learning, and matrix L is defined as Lik = δ ik ( 3x k2 − 1) − wik , (5) This updating algorithm will be used for the network learning as well as for retrieving the stored memories when applied patterns are just corrupted memorized ones. The actual values of elements in all the patterns are not the bipolar (-1 or +1) ones, but they are real values established in the network when it reaches its final state. These values are stable states that correspond to the minima of the double-well potentials for each oscillator. It should be underlined here, that fixed-point attractors in our case do not coincide, like in all Hopfield-type networks, with the corners of a hypercube,. The iteration learning procedure is constructed in such a way that applied patterns repeatedly presented one by one, but the next is presented only after the weight coefficients are adjusted according to the learning rule. The learning procedure lasts until MSE criterion ε will be less or equal some given small value. In all our simulations the obtained matrix practically coincides constructed from the key patterns ξ0 µ. We should underline here that in the coupling matrix 0 with the matrix wij constructed so far, all diagonal matrix elements wii are nonzero values. In Figure 8 is shown the dependence of MSE criterion ε on the number of iterations needed to learn, for a network with N=20 elements, the coupling matrix Wij . In Figure 9 is given the dependence of the sum of all matrix elements on the number of iterations for the network with N=20 units when only first pattern ξ1 is used to learn the network. Both dependencies characterize the rate of convergence process during the learning phase and point to an efficiency that significantly exceeds many classical Hopfield-type as well as feed-forward pattern classifiers, indicating a real-time potential for operating on image feature data, extracted by conventional DCT and wavelet techniques, that will run adequately on a platform such as currently available Pentium-based wearable PCs, as used in the TransPAC design (cf. Section 4).
  • 7. 2.5 2.0 1.5 MSE 1.0 0.5 0.0 0 2 4 6 8 10 12 14 Number of iteration (*100) Figure 8 Dependence of MSE on number of iterations needed to learn coupling matrix Wij for a network with N=20 elements 6 4 Sum W 2 0 -2 -4 0 2 4 6 8 10 12 14 Number of iteration (* 100) Figure 9 Rate of convergence of the learning phase. Dependence of sum of all matrix elements ∑ ij W on number of iterations for the network with N=20 units i, j The results presented in this paper and others () concern the computational possibilities of a network consisting of coupled bistable units that may store many more memory patterns in comparison with Hopfield-type neural networks. These new possibilities may be realized due to the proposed learning algorithm that may induce the system to learn efficiently. Using known patterns with up to 45%- 50% of distortions, the coupling matrix may be fully reconstructed. In some sense, the developed technique resembles a reconstruction of the dynamical system using its attractors. For example, a network composed of N coupled bistable units for a fixed coupling matrix has several stable fixed-point-like attractors that are associated with the memorized patterns. If these patterns and the coupling matrix are known, the applied patterns taken as the initial values for the dynamical system may be restored in few iterations. If some applied patterns belong to another set (e.g., they were obtained as a fixed-point attractors for different coupling matrix), they would be easily recognized giving
  • 8. another resulting coupling matrix that is updated during the retrieval phase. Therefore, the identification of memories (attractors) could be easily done. It was shown in simulations () that applied patterns with 45% of distortions may be effectively restored. If only memorized patterns are known the coupling matrix will be reconstructed after several iterations. In both cases the updating procedure for the coupling matrix uses the minimization of the least-mean-squares errors between the applied and desired patterns. From a computational point of view the proposed network offers definite advantages in comparison with the traditional Hopfield-type networks. It has good performance, it may learn efficiently, and has bigger memory capacity. In examples described above we have seen that the network with N=8 elements may store seven stable patterns that may be perfectly retrieved even when half of its elements are distorted by inversion of their signs. It should be said also that the performance of this learning algorithm depends on a judicious choice of the rule parameter η. It is worthy to underline that the network may operate also in a noisy environment, and for this reason it is useful for the MODE-based imaging. Recognition of linear, angular, and area features indicative of magnetic variations that are themselves indicatorsof stress, corrosion, or cracking in a metallic sample are intensely subject to confusion due to noise introduced by movements of the scanner and by microscopic distortions in the placement of the scanner at the time of image frame capture. It is necessary to compare temporally adjacent images for comparison as well as to compare detected features against a template library of learned feature types and the SONON algorithm can provide a tool for this task. 4. THE TransPAC™ MOBILE NDT SYSTEM Notwithstanding superior magneto-optics and image recognition, there is a further need to be able to perform many imaging tasks in diverse physical environments, locations, timings, and with more ease of use than afforded by existing alternatives. The TransPAC system was designed in order to provide a field-ready, robust computer platform capable of handling one or more types of video-based scanners including the MagVision and commercial variants currently being implemented. TransPAC is illustrated by Figure 10 which shows the operational scheme and organization of components. At the heart is a standard wearable personal computer running Windows 95/98 and capable of being worn on the body or in a backpack or beltpack. Several commercial models are available (Mentis, Via-II, Xybernaut) and the prototype TransPAC is being designed to accommodate more than one vendor’s product line in keeping with a philosophy of platform and product independence. The Mentis model (hardware produced by Interactive Solutions, Inc.) was selected for its physical ruggedness and hardware expandability. Aside from the NDT/NDI applications, the TransPAC is very much of a conventional portable PC, offering much the same as a notebook PC in capabilities, for data collection or other types of field work but with speech and smart card security options built into the design (cf. Section 4.3). For NDT/NDI there are two additional components – the MagVision NDT Scanner set and the MagVision NDT Tools software application. 4.1 MagVision NDT Scanner This set of two hardware plug-in modules consists of a sensor and video capture module which has a changeable scanner unit similar to that illustrated in Figure 11 below, and a pulsed current generator module. The scanner module enables the user to change the actual sensor wafer element in order to afford either optical and magnetic imaging or only magnetic imaging, to modify the size of the sensor and the magnification of the video image, and to modify the strength of an external magentic field if one is used for nonmagnetic and non-current-driven applications. The objective of the multiplicity of scanner features is to provide versatility for the end user. One TransPAC system with several attachments can serve for many different jobs in the field and enables the technician to try different techniques on the same sample while still at the inspection site. The pulsed current module serves to provide a variable amplitude and variable duration current pulse that is applied to nonmagnetic surfaces being imaged. It’s power supply is independent from the TransPAC while the control is driven by the user through the PC using a handheld infrared control. This affords the benefit of synchronous PC-centered control of the generator and current application while maintained electrical separation of the devices for safety and electronics sensitivity considerations. 4.2 MagVision NDT Tools MagVision NDT Tools is a Windows 95/98 application that provides complete test event logging with image processing capabilities and a built-in database from which records and tables can be rapidly uploaded to a server or another PC on a LAN or by modem after work completion. Figure 12 provides an illustration of the Verite image comparison module that enables a user to rapidly compare visually and with onboard automatic comparison the features of an image just taken with the TransPAC and one that is from a previous test or else a master template used to help determine both defect features in the sample being imaged and also calibration of the scanner system.
  • 9. CRT or Beltpack or LCD Bodypack Display Carrying Unit Microphone Base System AC Unit Power Headphone Adapter s Extension Pack Kbd / Mouse CD/DVD/Tape Unit Battery Pack Wireless Cell Phone Modem RS232 & Video Input PCMCIA Parallel Device(s) Data Acq Acquisition (MagVision) Device(s) Figure 10 TransPAC™ System Components The operator has the capability of viewing a maximum of four separate images that can derive from either the active scanner, disk file, or internet sources. Any one image can be compared with another by using a variety of user-configurable algorithms built in to the application – edge enhancement, area texture analysis, Fourier, Gabor, wavelet, and neural network tools are available for use with the image as a whole or for a user-selected rectangular region. The primary use of this tool is to enable the operator to rapidly isolate and identify interesting features and to bring out highlights in images while the NDI operation is ongoing. With additional features, described in Section 4.3, the user can maximize the opportunity to investigate other regions of the observed structure, whether the system is (as at present) purely under manual control and manipulation or being run by an autonomous agent as in a surface crawling robot.
  • 10. Figure 11 TransPAC with MagVision scanner unit Figure 12 Verite™ Image Comparator Application 4.3 Speech, Security, CADD, and Online Communications Most wearable personal computers have the capability for a keyboard interface and also a pen-based input. This may suffice for many conventional data collection tasks. However, to make the imposition that an NDT/NDI technician operating in potentially adverse and dangerous conditions outdoors and with the concern for correct placement of the MODE scanner and the pulse current generator must use a handheld type of keyboard or tablet is inappropriate given the alternatives. With recent and current in-the-field magneto-optic and ultrasonic NDT equipment, more extensive positioning and arranging has been necessary, mitigating the issue of rapid hands-free command operation and repetitive sequencing or images, but with the compactness of the MagVision components, as low as 3 in. by 3 in. and under 8 oz. weight, less cable, it becomes desirable to have as compact and easy to use a field computer as possible. TransPAC uses a complete speech-to-text-to-database command interface that supplements rather than replaces the pen/keyboard/mouse channel. This speech interface provides for a trained vocabulary of approximately 100 words that are speaker-independent and resilient to external noise and in particular speaker accent, tone, and volume variations and also non-verbal noise such as that from operating machinery. The software is used within a widely-accepted transportation data
  • 11. 2 collection product for highway and urban roadside asset data collection and has demonstrated the rigors of tests with variable speakers and noise levels. The voice stream along with other sensor data including an optional laser range finder, GPS, and digital camera is input along with the video data stream from the MagVision scanner module into a data recording application that organizes the respective elements into a record structure. This record structure undergoes an automatic quality assurance test which can optionally include the audio feedback, through headset earphones, of all speech input and all record field data for operator approval. Once manually or automatically approved, the record data including NDT images and any on-site real-time interpretation is output into an Access database for future use including direct uploading to a server. The roles of the GPS and laser range finder depend upon the NDT application. For certain outdoor inspection tasks (aircraft, tanks, pipelines, ships, bridges, highway poles, transmission towers) it may be necessary to reference the location of the test and the artifact/structure being imaged. A variety of GPS units with as much as sub-meter accuracy may be employed with TransPAC. One such system is the Trimble Pro XRS 1m real-time or post-process 12-channel GPS/DGPS receiver and antenna which is typically worn by the operator in a convenient backpack with no interference to physical movement or the operation of the TransPAC and the MagVision modules. The TransPAC display capability includes three options – a standard flat-panel screen that can be worn with a harness allowing full frontal large-scale viewing during operation, a flat-panel screen with flexible hose attachments that enables the display unit to be placed in a convenient location on a vertical or horizontal pile or strut, and a headset eyepiece display capable of the same full 800x600 resolution as the flat-panel displays. The former two approaches require a VGA cable running from the main TransPAC computer whereas the headset unit has a cable for video and two-way audio that will not interfere with operator hand or foot mobility. The role of the 16-bit 16K microprocessor smart card within TransPAC is twofold. First it serves as a compact and reliable form of access security for the system, identifying the operator and thereby setting up all access parameters for online network or internet linkages while the TransPAC is being used on an inspection assignment. The issue of security and traceability is of paramount importance from the larger-scale systems engineering and business process perspective in that a widely-deployed, operator-intensive NDT/NDI activity puts more weight and responsibility on the persons doing the tests and demands more accountability than activities which heretofore may have depended upon special planning and a special team of experts. As the operation of MODE-based NDT/NDI becomes more ubiquitous, the risks of human organizational error increase and this form of security, already built into TransPAC for other applications, 3 is an apt response. Currently the TransPAC has an industry-standard PCMCIA Type II interface for the smart card device. The card remains in the unit during all times of operation. 5. CONCLUSION A prototype system for inspection of metal fatigue and defects has been designed and constructed for field testing on aircraft, tanks, pipes, and bridges. A neural-like algorithm demonstrates progress toward the identification of image regions requiring enhancement due to noise introduced by movement or irregularities in the physical imaging process, and the same algorithm and software demonstrates improvements in automated detection of critical features that may be missed by a human observer conducting real-time inspection and analysis. The MODE magneto-optic sensor performs robustly in a variety of physical environments including the presence of layers of dirt, ice, and other non-homogeneous thin layers over the surface of the scanned sample. By use of a compact yet desktop-compatible PC as an imaging platform, the apparatus is useable in both mobile and robotic (9) applications. Further research is being focused upon the refinement and validation of the recognition software in order to provide additional semi-automated image recognition capabilities to the system. 2 VoCarta by Datria Systems, Inc. , Englewood, CO 3 primarily in health care (bedside and home visits), automotive service and inspection, and inventory control
  • 12. 6. ACKNOWLEDGEMENTS This work was supported jointly by internal funding from Silicon Dominion Computing, Inc. of Richmond, Virginia, and MODIS Corporation of Reston, Virginia. 7. REFERENCES 1. Chervonenkis A. Ya. & Randoshkin V.V., Applied Magnetooptics, Energoatomizdat, Moscow, 1990 (in Russian) 2. Chervonenkis, A. Ya., “Magneto-optic visualization of spatial inhomogenous magnetic fields”, Proc. ISMO, Kharkov, Russia, 1991, 10-34 3. Fitzpatrick G. L., “Novel eddy current field modulation if magneto-optic films for real time imaging of fatigue cracks and hidden corrosion”, SPIE Proceedings, Vol. 2001, 210-222, 1993. 4. Fitzpatrick, G. L., Thome, D. K., Skaugset, R. L., Shih, E. Y., Shih, W. C., "Novel Eddy Current Field Modulations of Magneto-optic Garnet Films for Real-Time Imaging of Fatigue Cracks and Hidden Corrosion," The International Society for Optical Engineering - SPIE Proceedings, 1993, Vol. 2001, pp. 210-222. 5. Fitzpatrick, G. L., Thome, D.K., Skaugset, R. L., Shih, W. C., "Magneto-Optic/Eddy Current Imaging of Subsurface Corrosion and Fatigue Cracks in Aging Aircraft”, in Review of Progress in Quantitative Nondestructive Evaluation, Vol. 15, edited by D.O. Thompson and D.E. Chimenti, Plenum Press, NY, 1996. 6. Fitzpatrick, G. L., Thome, D. K., Skaugset, R. L., Shih, W. C., "Detection of Cracks Under Cladding Using Magneto-Optic Imaging and Rotating In-plane Magnetization”, The International Society for Optical Engineering - SPIE Proceedings, December, 1996, Vol. 2947, pp. 106-115. 7. Dudziak, M. J. & Chervonenkis, A. Ya., “A Family of Microinstruments for Smart Materials, Energy Management, and Biomedicine in Space Missions”, Int’l Conference on Integrated Nano/Microtechnology for Space Applications, Houston, Nov. 1-6, 1998 8. Davis, C. W., Fulton, J. P., Nath, S., and Namkung, M., “Combined Investigation of Eddy Current and Ultrasonic Techniques for Composite Materials NDE”, Review of Progress in Quantitative Nondestructive Evaluation, Vol. 14B, Snowmass, Colorado, July 1994, pp. 1295-1301 9. Lozev, M. G., MacLaurin, C. C., Butts, M. L., and Inigo, R. M., “Prototype Crawling Robotics System for Remote Visual Inspection of High-Mast Light Poles”, Virginia Transportation Research Council, Report FHWA/VTRC 98R2, July 1997 10. A. Chervonenkis and M. Dudziak, 1998, “High Sensitivity Magneto-Optic Devices for Weak Magnetic Field Measurements and Localization”, 2nd Magneto-Optics Conference and Workshop, Moscow State University (preprint available 10/98) 11. M. Dudziak and A. Chervonenkis 1998, “Structural Integrity Inspection and Monitoring Using Magneto-Optic Sensors”, SPIE 1998 Symposium on Intelligent Systems and Advanced Manufacturing, 11/98 (preprint available 11/98) 12. V. Chinarov and T. Gergely 1997, “Non-equilibrium dynamics and synchronization in ensembles of interacting neural nets”, AeroScience 97, Orlando, FL 13. V. Chinarov and T. Gergely 1998, “Patterns of Synchronous and Asynchronous Behavior in Heterogenous Active Networks”, Massively Parallel Computing Systems 98, Colorado Springs, CO 14. V. Chinarov 1998, “Modelling self-organization processes in non-equilibrium neural networks”, SAMS, 30, 311-329