SEMINAR REPORT 2012

TV HOLOGRAPHY FOR THE NDE

CHAPTER 1

INTRODUCTION
The industrial application of holographic nondestructive testing (HNDT) is well established in the fields like tyre testing, bond testing of composite materials, early detection of fatigue and vibration analysis of structure. But the technique has certain limitations such as, stringent vibration isolation requirement, formation of extraneous fringes due to rigid body motion, difficulty in obtaining in plane and out of plane components, dark room facility and wet processing requirements, incapability of online quality inspection under industrial condition, etc. The newly emerged TV Holography technique, based on electronic speckle pattern interferometry, is a very effective alternate NDE tool. Initially the speckle was observed as a nuisance in laser holography but later it was observed that valuable information on the properties of object surface are hidden in it. This aspect was later used in the development of TV holography technique and its application for NDE. In the present work, the TV holography technique is applied for the NDE of a low modulus material used as insulator in solid rocket motor. This technique is most suited since; it offers real time inspection for quality assurance and is less affected by rigid body motion. TV holography technique using both mechanical and thermal loading has been studied and a practical methodology has been developed for defect sizing and characterization.

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SEMINAR REPORT 2012

TV HOLOGRAPHY FOR THE NDE

CHAPTER 2

HOLOGRAPHY
Holography is a technique that allows the light scattered from an object to be recorded and later reconstructed so that when an imaging system (a camera or an eye) is placed in the reconstructed beam, an image of the object will be seen even when the object is no longer present. The image changes as the position and orientation of the viewing system changes in exactly the same way as if the object were still present, thus making the image appear three-dimensional. The holographic recording itself is not an image it consists of an apparently random structure of varying intensity, density or profile. When a coherent beam strikes an object it is reflected in many directions, and the reflected wave fronts have a complicated shape. What we actually see is determined by the particular part of the wave front that enters the pupil of our eye. As long as our eye remains stationary the shape of the intercepted wavefront is unchanged, and the effect looks exactly the same. But if we change our viewpoint our eye intercepts a different portion of the wavefront, and the object looks different. Stereoscopic photography (stereophotography) exploits this phenomenon. Two photographs taken from the position of our two eyes about 7cm apart each is presented to the appropriate eye, forming a stereoscopic image. Although each photograph records only part of the information contained in the wavefronts this is still sufficient to provide; illusion of depth. Nevertheless, it is only part of the information; the viewpoint is fixed. The 1 way to provide all of the information is to record the shape of entire wavefront - and then to reconstruct the wavefront from the record. A photograph cannot accomplish this; nor for that matter, can a video record, nor any conventional device using a lens and light sensitive material. This is because the

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SEMINAR REPORT 2012

TV HOLOGRAPHY FOR THE NDE

frequency of the light wave is so high that there is no way of recording their fluctuations; only the time-averaged intensity is recorded. The phase information is lost. But it is the phase relationships of the various parts of the wavefront reflected by the object that carry the information about the distance of each point on the object from the film - the third dimension and the wavefronts are traveling at 3 x 108m/s. This is where holography comes into play. It mixes a second light beam with the beam reflected from the object, or object beam. This second beam, known as the reference beam, is derived from the same laser usually by a partly reflecting mirror or beam splitter. It has the same wavelength, and it travels at the same speed, because the two beams interact with one another to form an interference pattern, and although the wavefronts continue to travel at the speed of light,- the pattern itself is stationary. A hologram is a record of this pattern contains all phase information that is missing from a photographic record.

2.1. INTERFERENCE
A coherent source produces a beam that appears to have originated from a single point and is monochromatic. The lasers used in holography possess both aspects of coherence to a high degree. The distance over which the wavefronts remain in phase is called the coherence length; helium-neon (He-Ne) lasers used by semi professional holographers have a coherence length of some 250 mm (10in) or more, and the argonion lasers used by professional holographers have a coherence length of 3m (10ft) or more. The latest generation of semiconductor-driven lasers (see p. 156) has a coherence length of more than 3m. By comparison, the coherence length of sodium light is only about 0.3 mm. Light sources with poor coherence qualities are not suitable for holography. Wherever two coherent wavefronts are superposed, an interference pattern is created. At each point the resultant intensity represents the sum of the two waves at that point. Thus where the waves are in phase (peaks coincide with peaks and troughs with

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SEMINAR REPORT 2012

TV HOLOGRAPHY FOR THE NDE

troughs) there will be a maximum of intensity. This is known as constructive interference. Where the wavefronts are in antiphase (peaks from one source coincide with troughs from the other and vice versa) there will be a minimum of intensity. This is known as destructive interference. The light and dark regions of the pattern thus correspond to the in phase and anti phase states of the two wave-fronts, respectively. In between these maxima and minima there will be a gradual change in intensity as the relative phases of the two wavefronts change. If the amplitude and phase of the two wavefronts are known the amplitude and phase of the resultant can be deduced. Furthermore, if the amplitude and phase of just one of the component wavefronts is known and a record of the amplitude and phase of the resultant available, the amplitude and phase of the other component wavefront can be calculated.
2.1.1. ENCODING PHASE AND AMPLITUDE

Holography does provide such a record. We can demonstrate this using a laser beam and a piece of optical equipment called a Fresnel biprism. This is a pair of very thin prisms made to back from a single piece of glass, and it is often used to demonstrate interference patterns large enough to be visible to unaided eye. If we expand a laser beam by means of a concave lens and place the Fresnel biprism symmetrically across the disk of light we will be able to see the parallel bands of the interference pattern. These are known as interference fringes. If we place a piece of white card in the beam and then angle the card, we can spread out fringes so that we can see them quite easily. The dark fringes correspond to regions where the wavefronts interfere destructively, the light fringes correspond to regions where they interfere constructively. The fringes may have some messy marks on them, caused by dirt in the optical system, but they will be straight, because both halves of the beam consist of plane waves

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SEMINAR REPORT 2012

TV HOLOGRAPHY FOR THE NDE

Now take a fine sewing needle or a straight piece of fuse wire and set it in a piece of modeling clay so that it sticks up obliquely in the path of one of the beams, between the biprism and the screen. We will see that a small distortion has appeared in the fringe pattern. This distortion represents an alteration in phase in part of the object wavefront due to the presence of the object. If we now replace needle by a glass object such as a glass animal, the pattern become much more fragmented; nevertheless, it has still recorded the wavefront. precise disturbance in the object

To the permanent record of this, all we need to do is to substitute lens

with photographic film for the screen and, when it has received sufficient exposure, remove and process it. We now have a record which contains all the information about the object wavefront-a hologram. If we do not have access to a Fresnel biprism, we can produce the same effect with an optical arrangement known as Lloyd's mirror. This uses a large sheet of glass placed at a very shallow grazing angle in one half of the beam, directing it into the other half on the screen. We won't be able to get the angle between the two parts of the beam as small as we can with the Fresnel biprism, and we may have to turn the card to a very steep angle to the beam in order to spread the interference fringes out sufficiently to be viewed properly.

2.2. RETRIEVING THE IMAGE

The process of capturing the information carried in the shape of the object-beam wavefront is a fairly simple. All we need is a reference beam to mix with the object beam and a photographic film to record the resulting interference pattern. Having developed the film, all we need to do to recover the visual information is to put the film back in the reference beam in its original position, and it will re-create the beam as it came from the object.

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SEMINAR REPORT 2012 2.2.1. DIFFRACTION

TV HOLOGRAPHY FOR THE NDE

Diffraction occurs whenever a wavefront encounters an obstacle. It shows itself as a change in direction, a change in the shape of the wavefront. The iridescent coloring of dragonflies, beetles and tropical butterflies, the 'eyes' in a peacock's tail feathers, the flashing hues of a CD record, the lustre of a pearl, all are produced by diffraction. All these objects contain orderly rows of microscopic scales, grooves or layers and they cause light transmitted or reflected by them to be spread out into a spectrum; this is how the colors are produced. The simplest possible grating is called a cosine grating and if we pass a laser beam through it three beams emerge One of these beams is just the undiffracted beam. The other two, one each side, emerge at an angle which depends on the wavelength of the light and on the spatial frequency of the grating. The angle is greater for longer wavelengths and higher spatial frequencies.
2.2.2 RECONSTRUCTING THE OBJECT BEAM

The interference pattern produced by the reference beam and the object beam, as recorded by a film, has also the transmitter profile of a cosine grating, though an irregular one because of irregularities of the object-beam wavefront. So when we direct the original reference beam onto the hologram it is also split in to the beams. One is the undiffracted beam, which passes straight the hologram. The second is the more diffracted beam. The third is the diffracted beam on the other side this is usually feeble. Because there are irregularities in the grating, the main diffracted beam is irregular too, but it is spread out purposefully, not randomly: it is a replica of the object beam. If we put our eye into this beam and look through the-grating we will see a view identical with that of the original subject, as if through a window. The grating produced is much too fine a pattern to be recorded in ordinary films and so there is a special ultra-high resolution film made for holography

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SEMINAR REPORT 2012

TV HOLOGRAPHY FOR THE NDE

CHAPTER 3

PRINCIPLE
In TV holography, the object and reference beams of a speckle interferometry set up is imagined by a CCD camera and the interference pattern is grabbed and stored as a digital image in a computer. Two speckle interferometry patterns of the test specimen are recorded in the initial state and after loading the object (IA,IB). The two images are electronically processed to produce correlation fringes, which are contours of constant phase changes corresponding to object movement. The deformation caused by defects in the material produce fringe anomaly, since there will be stress/strain concentration close to the defect. Even the subsurface and inner defects can generate a fringe anomaly if the loading is sufficient. The light intensity recorded in the image plane is a function of the reference and object wave fronts and can be expressed as IA = I1 + I2 + 2 I1 I2Cos (3.1)

where IA is the intensity distribution of the object in its initial state and is the random phase difference between the waves. If the object receives a static displacement, a phase change due to object deformation is introduced into the wave front and the intensity distribution can be expressed as IB = I1 + I2 + 2 I1 I2Cos(+ ) The change in intensity due to the deformation can be obtained as I = IA- IB =4 I1 I2Sin(+ /2)Sin /2 (3.3) (3.2)

The image corresponding to I can be obtained by digital subtraction. The intensity of images displayed in the monitor is proportional to I and is maximum when =
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TV HOLOGRAPHY FOR THE NDE

(2n+l) and is minimum when =2n where n is an integer. This intensity change will appear as dark and bright fringes on the monitor. The fringes are formed due to the change in optical path length when the specimen is deformed. The phase change due to deformation of specimen is given as = 2 / X [w(1+Cos) + uSin] (3.4)

If the angle of illumination is small, equation is simplified to = 4w/, where w is the out of plane displacement component. When is equal and opposite, the in-plane displacement component is producing the phase change and the corresponding fringe pattern. = (4 uSin)/, where u is horizontal in plane displacement. = (4vSin)/, where v is vertical in plane displacement. (3.5) (3.6)

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SEMINAR REPORT 2012

TV HOLOGRAPHY FOR THE NDE

CHAPTER 4

EXPERIMENTAL SETUP
The experimental set up used for this study are shown in Fig. 4.1 and Fig.4.2 for the out of plane and in-plane displacement configurations. These methods are selected, since the setup is very compact and can be easily arranged for industrial application. The light from a continuous wave He-Ne laser of 25 mW is split into two using a plate beam splitter. One of the beams is used to illuminate the specimen and the other is made to fall on the reference surface. The object is imagined onto a CCD camera, which is connected to a host computer for processing the grabbed images. Fig. 4.1 shows the optical configuration sensitive to out of plane displacement.

Fig. 4.1 Optical Configuration for ESPI for out of plane displacement

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SEMINAR REPORT 2012

TV HOLOGRAPHY FOR THE NDE

The optical configuration of TV Holography for in plane displacement is shown in Fig.4.2. Here the two beams from the beam splitter is made to illuminate the specimen at an equal and opposite angle to the optic axis.

Fig. 4.2 Optical Configuration for ESPI for in plane displacement

4.1. CONTINUOUS ACQUISITION OF SPECKLEGRAMS

The data flow diagram developed for continuous acquisition of images is shown in fig 4.3. The frame grabber card properly installed in the system is operated for enabling the frame grabber item on the menu. This item on the frame grabber window has been selected for displaying live video images. After controlling frame grabber parameters such as grab size and input channel selection, the individual frames of the images are grabbed.

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SEMINAR REPORT 2012

TV HOLOGRAPHY FOR THE NDE

Fig. 4.3 Data flow diagram for continuous acquisition of images

The data flow diagram developed using different Imaging Graph operators is executed for continuous acquisition of live images under different loading conditions. This method of continuous acquisition is very effective for fixing the optimum load for getting visible fringe pattern after subtraction. The start operator is used as the starting point of an Imaging Graph, because most operators require at least one input. The acquire operator grabs a currently stored image from the frame grabber. The number of images for grabbing is decided by fixing the frames parameters. It is seen that if frames are set to one, then a single image is the output. If the number of frames selected is greater than one the sequence of images are grabbed and the output is obtained as a vector sum of the images. In this case, the delay parameter sets the time interval between images grabbed in sequence. The display operator creates a pop-up frame containing the data of the object received at its input port. If the object is an image, then the pop-up is presenting a rendered image. If the object is not an image, then display will pop-up a frame with text showing all the pertinent data contained within the object. The Charged Couple Device used is an interline-transfer colour video camera module designed for RGB image processing. It has high performance horizontal resolution of 570 TV lines with a signal to noise ratio of 58dB and sensitivity of 2000 Ix. The video capture card is capable of digitizing live images at

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TV HOLOGRAPHY FOR THE NDE

the rate of 30 frames/sec. The image processing system

used for the analysis of

fringe pattern is an algorithm developed by using Imaging Graphs.

4.2. ON-LINE GENERATION OF FRINGE PATTERN

In order to get fringe patterns, a large number of trial experiments are performed by deforming the specimen at different loading conditions. At each stage, the grabbed speckle gram of the specimen under loading condition is subtracted from the reference pattern. To avoid this time consuming and tedious process, a data flow diagram has been developed for continuous live subtraction of speckle grams for generating ESPI fringe pattern and is given in fig. 4.4. Here, the option is given either for subtraction or addition of frames. This algorithm is very effective for NDT applications in experimental stress analysis because the live fringe patterns with and without anomaly is instantly displayed on the monitor for further analysis and study.

Fig. 4.4 Data flow diagram for continuous subtraction or addition of images

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SEMINAR REPORT 2012

TV HOLOGRAPHY FOR THE NDE

CHAPTER 5

RESULTS AND ANALYSIS

5.1. MECHANICAL LOADING
A circular disc of 40mm diameter has been used as the specimen fixed at its periphery and subjected to a central mechanical load of 40mm. This loading condition has been arrived by trial and error, in order to get sufficient fringe density to view the interferogram. The speckle interferometry fringes are obtained by digital subtraction of speckle grams before and after loading. The electronic subtraction is done using the Image Compact software. Fig.5.1 shows the out of plane displacement fringes corresponding to a defect free specimen after image processing.

Fig. 5.1 Speckle Interference Pattern for Defect free specimen - Mechanical Load

A tight crack of 5mm length is introduced in the specimen and repeated the experiment. In this case the central loading required was only 10 mm to get the same order of fringes as in the defect free case. Fig 5.3. Shows the results of defective specimen after image processing. The location of crack is clearly visible as an
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anomaly in the fringe pattern. It was noticed that number of fringes increases from the crack site due to larger displacement.

Fig. 5.2 Speckle Interference Pattern for Defective specimen - Mechanical Load

5.2. THERMAL LOADING

The experiment has also been carried out using thermal loading. The specimen is heated using an IR lamp to produce a change in temperature about 10C above room temperature. The fringes corresponding to the specimen in the initial condition and after introducing a tight crack of 5mm length are given in Fig.4.3 and Fig.4.4. The fringes seen outside the specimen dimension are spurious fringes.

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Fig. 5.3.Speckle Interference Pattern for Defect free specimen with Thermal Load

Fig. 5.4. Speckle Interference Pattern for Defective specimen with Thermal Load

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TV HOLOGRAPHY FOR THE NDE

CHAPTER 6

CONCLUSION
The results of ESPI for NDE of low modulus materials used for rocket systems have been presented. Experimental results show that out of plane ESPI configuration can give an indication of even inner defects if they can influence the surface on loading. This method is highly sensitive, whole field and real time. The result shows that the technique as such can be applied to aerospace components such as solid rocket propellant, composite material, graphite etc.

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REFERENCES
1. A. Mujeeb, V. R. Ravindran and V. U. Nayar, "Studies on TV holography for the Non-destructive Evaluation (NDE) of space vehicle components", Proc. Fourteenth Kerala Science Congress, 2002. Pp 498-501.

2. Graham Saxby (1991), Manual of Practical Holography, ButterworthHeinemann Ltd. Pp 4-17. 3. P.Hariharan (1996), Optical Holography Principles, techniques and applications. 2nd Edition, Cambridge University Press. Pp 163-177. 4. Applications of Holography, Plenum press, NY-London,1971. Pp 105-115 5. A. Mujeeb, V.U. Nayar and V.R. Ravindran, A Method for Real Time and Continuous Acquisition of Interferogram of ESPI for Non-Destructive Evaluation , National Seminar on NDE , Hyderabad, 2006.

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