1. Introduction
In the case of inductive thermography, a short inductive heating pulse in the range of 0.05–1 s is applied to the work-piece and the surface temperature is recorded during and after the heating pulse by an infrared (IR) camera. Surface defects deflect the induced eddy currents and disturb the heat diffusion; therefore, the defects in metallic materials can be excellently detected by analyzing the infrared images [
1,
2,
3,
4,
5,
6]. In addition, this method has the advantage compared to other methods such as magnetic particle testing or penetration testing that it also provides information about the defect depth and about the inclination angle of a surface crack [
1].
Metallic surfaces often have a low emissivity value and inhomogeneous surface properties. Evaluating only one infrared image, e.g., at the end of the heating pulse, is strongly affected by this inhomogeneity and also by the inhomogeneity of the heating. This could cause false detections or on the other hand, missing detection of defects. However, recording a whole infrared sequence and evaluating the temporal change in the temperature provides the advantage of suppressing the inhomogeneity effects and it reduces the background noise in the images, resulting in a higher detection reliability. For the evaluation of the infrared sequence, often Fourier transformation is used to calculate a phase image, which is then used to localize and to characterize the defects [
7].
For the inspection of long work-pieces, scanning in a stop-and-go way, which is also called step scanning [
8], can be used. During one measurement, both the inductor and the recording infrared camera are stationary and after one measurement, either the work-piece or the heat source together with the IR camera are moved further to the next position. Afterwards, the separate measurement results are stitched together to one panorama image [
8,
9]. In this paper, a method is presented to optimize this technique by applying a calibration object for rectifying the images. As we have applied this method to a rail piece where the defects occur at the curved surface of the gauge line, the calibration object was also used to reduce errors in the stitching caused by the rail curvature.
Another possibility for the inspection of long pieces is a scan with continuous motion [
9,
10,
11,
12], where either the work-piece is moved with a constant speed and the heat source together with the infrared camera are stationary, or the reverse. During this relative motion, the infrared camera always records the temperature of different parts of the inspected work-piece; therefore, an additional step is necessary to generate a phase image. The pixels in the recorded infrared images are reorganized in a way, as they belong to the same position of the work-piece, as it would be the case for a stationary measurement. This allows for the application of the same evaluation method of Fourier transformation, as it has been developed for stationary measurements [
11].
The scanning pulse phase thermography, SPPT [
11], works very well for the detection of subsurface defects. In this case, only the temperature changes after the heating pulses are evaluated. The heat is generated due to the induced eddy currents in a thin depth at and below the surface and the heat travels into the body. If there is a defect, then the heat diffusion is disturbed and the perturbation in the surface temperature can be observed with a time delay after the heating pulse. Therefore, the most relevant information regarding the defect detection is contained in the temperature change recorded after the heating pulse [
13]. For surface cracks, the situation is different and the most important part of the information is included in the temperature change during the heating, as the perturbation due the surface crack occurs instantly at the surface. If the induction coil during the scanning covers the surface, then due to this occlusion, the infrared camera cannot record the temperature during the heating. A method has been developed, which is presented in this paper, where the camera is mounted tilted at an angle to the specimen’s surface, so that the specimen’s movement underneath the induction coil is in frame. This allows for the recording of the temperature during the heating process. Furthermore, a calibration object is used to rectify the infrared camera images, in order to allow for the reordering of the pixels and the calculation of the phase image.
The structure of this paper is the following: after this introduction, the rail pieces are described, which we used to demonstrate the new developments for the inductive scanning thermography technique. Then, the two experimental setups for stop-and-go and for continuous scanning are described in
Section 3. The used calibration objects and the applied rectification procedures are presented in
Section 4. The performed measurements of the two rail pieces in stop-and-go motion and in continuous motion are described in the fifth and sixth Section. The results of the presented method are then discussed and summarized in
Section 7.
2. Description of Specimens
To demonstrate the advantages of the scanning inductive thermography, two rail pieces with rolling contact fatigue (RCF) defects were used. As described in a recent publication, head checks and squats are common defects on rails, stemming from rolling contact fatigue (RCF) [
9].
Head checks are a material fatigue phenomenon caused by the high contact stresses between the wheel and the gauge corner of the rail that occur in sections of track with a curve radius between 500 m and 3000 m. They appear as fine surface cracks that occur at discrete intervals that grow into the rail head with a very shallow entry angle (10–30 degrees). Squats are rolling contact fatigue (RCF) defects that occur in straight or (gently) curved track within the running band on the rail head, where the rail is heavily sheared. This specific defect phenomenon is thought to be initiated via small parts of hard material (such as pieces of track ballast) that are caught between the rail and wheel and cause certain cracks to grow. The crack then preferentially grows in the direction of the heavily sheared surface layer; this generates the characteristic round shape of the squat. For a more detailed description of head checks and squats, one can refer to [
9] and the references therein.
A 250 mm long piece of rail with head checks on the gauge corner (RP01; see
Figure 1) was used for the scanning in stop-and-go technique. The rail piece was provided from voestalpine Rail Technology GmbH and it is a cut out piece of a decommissioned pearlitic rail from the Austrian railway system. A characterization of the head checks on this specific rail piece was published in [
9]. The average distance between the head checks was determined as 2.54 mm and an average length of head checks as 17.1 mm.
The specimen used for continuous scanning is a 300 mm long pearlitic rail piece with squats (RP02; see
Figure 2). The specimen has two large squats, which are clearly visible and some small and shallow cracks in the earlier stages of crack progression. These ones are not or only barely visible. The specimen is also a cut-out part of a decommissioned rail piece found in the Austrian railway system, provided by voestalpine Rail Technology GmbH.
Table 1 presents a short summary of both rail pieces and shows the short names that will further be used in this work to reference the specimens.
3. Experimental Setup
In the experimental setups, a high frequency (HF) induction generator with 5 kW power was used. Depending on the attached inductor, the excitation frequency is in the range between 100 and 200 kHz. The specimen is placed on a linear table and moved via a linear actuator providing motion speeds up to 250 mm/s.
For the measurements, the IRCAM Velox 1310k SM, a cooled infrared camera with an InSb detector, was used. In standard full-window mode, the camera records 180 images per second with 1280 × 1024 pixels. By changing to binning mode, the number of pixels is reduced to 640 × 512 for the same field-of-view (FOV), as 2 × 2 pixels are recorded together. In binning mode, the frame rate is increased to 600 images per second. To test the limits of the new SPPT approach, additional measurements were carried out with a much slower µ-bolometer camera (FLIR A615), recording 50 images per second with 640 × 480 pixels. This camera has the option of increasing its frame rate to 100 or 200 images per second by restricting the number of recorded pixel rows to 240 or 120, respectively. A µ-bolometer camera is slower and has lower temperature resolution than the cooled InSb detector, but it does not require cooling, which makes this camera type more advantageous in an industrial environment.
3.1. Setup for Stop-and-Go Technique
Figure 3a shows the setup for scanning in the stop-and-go approach. A so-called Helmholtz coil is used to heat the specimen RP01. This type of coil induces the eddy current almost homogenously in a larger region inside the coil. Therefore, it is often used in stationary pulse phase thermography.
The camera is placed on one side of the linear table looking at the gauge corner of the rail piece inside the Helmholtz coil. The distance between camera and specimen is approximately 250 mm. The specimen is positioned so that a motion through the coil is possible and eddy current excitation inside the coil heats the surface of the rail gauge corner between 0.8 and 1.5 K during a pulse length of 0.3 s.
3.2. Setup for Continuous Scanning
The setup for continuous scanning is shown in
Figure 3b. RP02 is positioned on the linear table and the line heating source is placed above the rail piece and perpendicular to the motion direction. The line heating source is equipped with an additional field concentrator, which focuses the magnetic field into the specimen below. The overall width of the inductor is 20 mm.
The camera is positioned behind the induction coil tilted in a 60-degree angle to the surface of the specimen. The distance between the induction coil and the specimen beneath was set to approximately 40 mm, so that the heated surface area of the specimen below the coil can be viewed and recorded by the IR camera.
7. Discussion and Conclusions
Both shown scanning methods with the rectification of images and sequences can be used on long specimens with a constant contour surface profile. Scanning with a stop-and-go motion consists of multiple stationary measurements. Therefore, all evaluation methods developed for phase images, e.g., detection of defects or characterization of their length or depth [
9], can also be applied on the panoramic phase image. Continuous scanning is a faster technique, which allows for the quick detection and localization of surface defects but detectability will be affected/limited by the relation between the scanning speed and possible frame rate (see the following sections).
7.1. Checkerboard Grids
A checkerboard grid printed on paper is a fast way to generate a bendable calibration target with different sizes of the printed squares. The ink is also visible for cameras in the visible spectrum. Thus, a registration of an infrared camera and a visible camera is possible with printed calibration targets. However, the contrast of ink on the paper is not high in the infrared spectrum, so it is difficult to record calibration images with a high enough quality for the detection of all the checkerboard points automatically. Different types of paper or different colors of ink could have a better contrast. This will be investigated in further works.
The checkerboard grid made from a metallic plate and adhesive film shows a good contrast in the infrared spectrum. The image processing routine can reliably detect the checkerboard points on this calibration target. In this work, in a visible range, transparent adhesive film was used to create the checkerboards, so a camera in the visible spectrum cannot detect the grid. However, colored adhesive film is available and newly created checkerboard grids will be visible for both camera types.
7.2. Scanning in Stop-and-Go Motion
For this type of scan, a bendable checkerboard grid is used to rectify the surface profile of a long specimen. If the specimen between two measurements was moved also up and down or closer or further away from the camera, then this would lead to wrong rectification results. Therefore, setting up the specimen in relation to the camera correctly, i.e., at a fixed distance during the motion, is crucial for this type of measurement. This means that preparations for this type of scanning are rather time consuming. The benefit of this type of scan is that segments can be evaluated individually and the original recorded image sequences are not changed. Transformations are performed on the resulting phase images and all necessary information for creating the panoramic image can be stored separately. The segments can be evaluated separately or as a panoramic image. The methods for the characterization of head checks on this particular specimen were already published in an earlier work [
9].
7.3. Scanning in Continuous Motion
The continuous scanning method is a fast way of inspecting long specimens. With the reorganization of the image sequence, the evaluation of a phase image is possible. The size of surface defects detectable with this method depends on various parameters and some of them are discussed in this section.
- I.
Temperature increases and motion speed:Figure 17 compares the temperature increase in the case of three different motion speeds, determined for the position close to the defect, after reordering the recorded IR sequence. The temperature increase due to the inductive heating is affected by the motion speed through the heating region of the inductor. Slower speed causes a longer excitation period and, therefore, higher temperature increase. In the transformed quasi stationary sequence, it can be observed that temperature curves look similar to that of stationary pulse measurements. The duration of these pseudo-pulses can be approximated by the time of how long the specimen needs to go through the effective heating range underneath the inductor. For motion speeds of 100, 150 and 200 mm/s and an effective heating range of inductor with a width of 20 mm, this results in pulse durations of approximately 0.1, 0.15 and 0.2 s, respectively (see
Figure 17d).
- II.
Camera frame rate and image resolution: As described in [
11], during the transformation to the quasi stationary sequence, the size of the images and the number of the frames are changed. The new image size in motion direction
x is determined by the pixel columns running through the entire camera’s FOV. This can be calculated by multiplying the number of frames in the original sequence and the shift
s, as in
Figure 18. However, if the shift
s significantly deviates from an ideal shift of 1 px, this calculation is inaccurate due to interpolation during the transformation. Therefore, through this transformation, the camera’s frame rate impacts the spatial resolution of the transformed images. The number of frames in the transformed sequence is the quotient of
nx, the number of pixels in motion direction in the original sequence and the shift
s (see
Figure 18). This means that the spatial resolution of the original image affects the temporal resolution of the created sequence.
- III.
Evaluation with phase image: For the calculation of the phase with Fourier transform, the images recorded during the heating pulse and afterwards during the cool-down are used. The following question arises: how many images during the cool- down should be considered? Earlier works show [
7] that for phase images, the relationship between pulse length and cool-down-period influences the result. For stationary measurements, often a cool-down-period with the same length as the heating pulse itself is chosen. As described in point II for scanning, this is not so much a temporal length as it is rather a spatial length. This means that the recorded area underneath the inductor resembles the pulse length and the recorded area behind the inductor resembles the cool-down-period. In the case of the measurement in
Figure 16, a distance of 45 mm in the moving direction was covert by the camera’s FOV, from this 15 mm underneath the inductor and 30 mm behind the inductor. Therefore, the resulting phase image is an evaluation of a certain pulse length and additionally a cool-down-period, which is two times longer than the pulse length. Since the FOV needed for phase evaluation is rather small, it is possible to reduce the camera’s image size in y-direction, which further allows for higher frame rates and, thus, increasing the resolution of the result.
All the described parameters are interdependent. The frame rate of the used camera speed is an important factor to change and test different parameter settings. Future research will discuss the detectability of small surface defects with this modified SPPT method with a focus on the three described parameters. Cooled camera systems with high resolution and high frame rates are, of course, beneficial for this type of testing; however, uncooled systems with higher frame rates show also high potential for such scanning applications and are more suitable for mobile inspection setups.
Figure 19 shows that a moving speed of 150 mm/s still provided a decent result with a high speed uncooled camera system.