Vladimir Vavilov

Tomsk Polytechnic University, Russia

vavilov@introscopy.tpu.ru
1-1 Some Basic Statements

Infrared Thermography is the technique allowing non-contact imaging of

temperature distributions by infrared (thermal) radiation of bodies.
Infared thermography has been an acknowledged technique in technical
diagnostics (condition monitoring & predictive maintenance). Presently this
technique has been becoming an important tool of nondestructive testing of
materials with subsurface defects.
Passive mode of Thermal NDT requires only using infrared cameras
(imagers). There are non-radiometric (imaging) and radiometric (measuring
temperature) IR cameras on the market.
Recently, a new generation of IR imagers appeared, particularly, those using
Focal Plane Array (FPA) detectors, including Quantum Well Photodetectors
(QWIP).
Active mode of Thermal NDT involves additional thermal stimulation of
objects under test. Several types of heaters (coolers) are used in combination
with IR cameras and computer stations.
Computer station
1-2 Infrared System Presentation

Atmosphere

Infrared
imager

Object to be tested
Nondestructive Testing
(NDT) of Materials
(thermal stimulation is
Processing software required)

Military Night Vision (Civil)

Technical Diagnostics
Reconnaissance Search & Rescue
Night vision Observation Predictive Maintenance
Self-guiding missiles Alarm systems Condition Monitoring
Detecting landmines Night driving
 Infrared Thermography:
1-3 Electromagnetic Spectrum
Ultraviolet radiation
Gamma
radiation
Visual
X rays
Cosmic rays (0.35-0.75 mm) Radiowaves

Infrared (thermal)
radiation
0.75-1000 mm

3-5 mm (Short Wave) and 7-13 mm (Long Wave) wavelength

bands are typically used in IR thermography
1-4
IR Detectors & Modules

BAE Systems, U.S.A.

640x512 QWIP Assembly
Operating temperature: 70K (Stirling engine)
NETD: 30 mK
Spectral response: 8-10 mm
ULIS, France.
UL 01 01 1
Uncooled microbolometer
(amorphous silicon)
Array format: 320 x 240
NETD=85 mK
Thermal time constant: 4 ms
Pixel size: 45 mm
Area fill-factor: 85%
Spectral response: 7-14 mm

A10 FLIR Systems

(former Omega from Indigo)
Image format: 160x120
Frame rate: 30 Hz
NETD=85 mK
Weight: 120 g
1-5 IR Imager Appearance (I, II)

Raytheon, U.S.A.

Hand held PalmIR Pro (no temperature

measurement; 320x240 long-wave
ferroelectric FPA detector; uncooled;
2,5” color LCD display; 8MB flash
memory (60 images); weight: 1.8 kg)

Digital Imaging Infrared, Inc.

U.S.A.

DVE-1000 (no temperature

measurement; 320x240 long-
wave ferroelectric FPA detector;
sensor weight: 1.5 kg;
recommended as a driving night
vision device)
1-6
IR Imager Appearance (III, IV)

Phoenix Indigo (FLIR Systems), U.S.A.
320x240 or 640x512 short-wave InSb FPA
detector; frame frequency 345 Hz (320x240),
101 Hz (640x512) and up to 38 kHz by
windowing the FPA; temperature resolution
25 mK; 14 bit
ThermaCAM P60 (FLIR Systems, U.S.A.)
Image format: 320х240. Temperature
resolution: 60 mK. Temperature range: –40
to +2000оС. Weight 2 kg. Combination with
video recording.
1-7 Russian IR Imagers
«IRTIS-200» («IRTIS-2000»)

Radiometric imager
Temperature range: –20 to +350оС
Image format: 256x256
Temperature resolution: 0.05оС
Frame frequency: 1 Hz
Mass: 1.8 kg
Price: US$18,0K
1-8 Infrared Imagers Using Quantum-Well Infrared
Photodetectors (QWIP)
Cooled QWIP: High Speed, High Resolution

Two imagers - Same target – Same temperature range

32.9°C 30.5°C

30
32
29

28
30

27

28 26

25
27.0°C 24.9°C

PtSi-based FPA imager QWIP-based FPA imager

(FLIR 12 bit ThermaCAM 390) (FLIR 14-bit SC 3000)
 1-9 Infrared Thermography:
Summarizing Remarks
Power of radiation
Maximum power is emitted at
increases with IR thermography typically uses two
a particular wavelength: the
temperature wavelength bands: 3 – 5.5 mm and
higher is the temperature, the
depending on a 7 – 14 mm
shorter is the wavelength of
wavelength band
maximum radiation
2 3
(~T4 – T9) 1
High-reflective and semi-transparent bodies are
‘bad’ objects for IR thermographic NDT. In 5
In IR thermography, the preference of
temperature measurements, the reflected and
a wavelength band is not unanimous.
transmitted components of thermal radiation should
Typically, LW imagers have better
be diminished.
integral sensitivity, but SW imagers
are more sensitive to small 4 The contribution of reflected
temperature variations (in particular, 6 radiation can be determined by using
on a noisy background) the ASTM Standard E 1862-97. The
contribution of transmitted radiation
The influence of emissivity on thermographic can be determined by using the
measurements is two-fold: ASTM Standard E 1897-97.
• in optical thermometry, only ‘radiation’ but
not ‘true’ temperature can be measured, The radiation of real bodies can be
• in diagnostics and NDT, emissivity variations enhanced by applying ‘black’
cause false indications
7 coatings 8
Military, surveillance, night vision, law
enforcement, predictive maintenance
& condition monitoring
2-1 Night Vision by Infrared Thermography
In 1999, world commercial and dual-use IR imaging systems had a market value of
US$600 million. In 2000, General Motors & Raytheon introduced IR cameras for night
driving (Cadillac DeVille 2000). By 2005, the market value is likely to increase to
US$2,600 million, mostly due to automotive uncooled night-vision systems.
 Standard Night Vision Equipment vs. IR Imaging Cameras

Standard Night Vision: IR Imagers:

Spectral region : 0.3-1.5 mm Spectral region : 3-14 mm
Distance: up to 100 m Distance: up to 3000 m
Price: US$1-3 K Price: US$3-12 K
 Detecting Leakages From Underground Pipelines
10-1
2-2

~0.5-1 m
! ~1.5-3 m
?

Image Courtesy Greg Stockton

2-3
Environment Monitoring

Detecting illegal waisting to a river

Image Courtesy Greg Stockton
 Обследование силового
Electricity электрооборудования
Distribution Systems (I)
10-1
2-4
10-1
2-5
Detecting Vacuum Deterioration in Power
Plant Turbine Vacuum Path
41,8°C

40

38

36

34

32
31,8°C

Temperature gradient 3оС

42,9°C

42

40

38

36

34
33,7°C

Temperature gradient 5оС

2-6 IR Thermographic Inspection of Buildings

Use of IR Thermography in building has no

alternative.
Applications:
Evaluation of building thermal protection (quality
of architectural and technological solutions)
Determining a k-value
Detecting envelope defects that appear as a result
of poor workmanship or during exploitation
Detecting roof moisture
 IR Thermographic Inspection of Buildings
2-7
Guidelines on the IR thermographic inspection
of building envelopes are approved in some
countries (Sweden, Finland, Canada, U.S.A.,
Russia, Great Britain, Germany)

In some Russian cities, IR thermographic inspection of new buildings is

obligatory by local laws

DT=+4oC

Vertical seam requires immediate repair

2-8 IR Thermographic Inspection of Buildings

Few Russian building

companies start to include
expenses on thermographic Internal inspection is more
Defect vertical seam inspection into building cost sensitive to defects
2-9
IR Thermographic Inspection of Buildings

Defect panels in
envelopes of power
plant buildings
might lead to
catastrophies
2-10
IR Thermographic Inspection of Building Roof (I)

Detecting water in the roof of a power plant main building

37,8°C 45,8°C

45

35
SP01 SP01
40

SP02 30
35
SP02

25
30

22,1°C 27,5°C
2-11
IR Thermographic Inspection of Building Roof (II)

Water
10-1
2-12
Airborne IR Thermographic Inspection of Building Roof

Image Courtesy Greg Stockton

 Expertise of Buildings
2-13
Inter-panel seams are of extremely
A map of defects is used in repair
poor quality

IR thermographic expertise can be used in court affairs

2-14 Investigating the Catastrophy Occurred
at Tomsk Military Academy (1997, 12 dead)

DT12=1.5oC 16,0 °C DT12=0.3oC 13,5 °C

16

.
1
15
. 1 13

. 2
14,0
14
. 2
11,5
12
2-15 Smokestack Inspection

Visual inspection performed by industrial

alpinists is expensive, unreliable and time-
consuming (but necessary)
In 1998, the United Electrical Networks of
Russia, the major producer of electrical power
in the country, allowed using IR inspection
instead of traditional visual inspection that is to
be performed once a year

In 1999-2004, the author surveyed over 50

smokestacks. Smokestack inspection is a
growing market.

In 2002, the «Guidelines on IR

thermographic inspection of smokestacks»
were approved in Russia
 Typical Smokestack Thermograms
2-16

40 m metallic 150 m concrete

smokestack with smokestack is
internal characterized by a
refractory. The circular pattern of the
destruction of temperature
the upper edge distribution. Porous
of the refractory concrete seams appear
is clearly seen cold. Degradation of
mineral wool insulation
results in warm areas.

50 m brick smokestack with plentiful

cracks. Oblique (horizontal) cracks are
most dangerous.
 AEROSPACE AND
OTHER APPLICATIONS
3-1

TNDT advantages: 1) inspection of both

metals and non-metals is possible, 2)
inspection rate is high, 3) inspection results
illustrative, 4) may be used in combination
with other techniques

TNDT is frequently used as a screening

technique

TNDT drawback: high level of noise and,

hence, difficulties in interpreting data

Sophisticated computer data processing

is necessary
3-2 Active Thermal NDT of Materials
3-3 TNDT System Components
 3-4 Active Thermal NDT Systems

Detecting
Inspecting On-Site
Buried
Atlas
Laboratory Thermal
Landmines
Space
flash inNDT
Launch
system Examples
Bosnia
Vehicle
Inspecting Aircraft for HiddenCorrosion
(courtesy D. Burleigh)
(courtesy X. Maldague)
3-5 Basic Theoretical Models
Layer 1 Layer 2
Defect – infinite layer
Heating function
Software for solving Thermal NDT
Layer 3
hf
problems
h
r
Heating Q
1D Model
th Commercial
z
Front
Mathematica
surface
l
L
d Rear
surface
MatLab
Ansys 2D Model
3D FemLab
Model et al. Q
Q Defect-parallelepiped
h Specialized Defect - disk
hf
ThermoCalc-3D Pro l R r
ThermoCalc-6L et al.
L d

rd

h z

hr
‘Classical’ and Novel Data Processing Techniques in Thermal NDT
3-6
Optimal Detection – signals over defects are to be monitored at their maximum signal-to-noise ratio time

Early Detection – signals over defects are to be monitored at earlier times when lateral heat diffusion is
minimal

Dynamic Thermal Tomography – the technique is based on the fact that deeper defects produce later
surface temperature signals, therefore, selecting delay times allows selecting sample layers

Pulse Phase Thermography – the pixel-based Fourier transformation in time allows producing images of
phase and magnitude (Wavelet Analysis is the option)

Defect Characterization – a set of algorithms allowing evaluating defect lateral dimensions, thickness and
depth

Polynomial fitting – smoothing noisy temporal evolutions with polynomials

Non-Linear Filtering – multi-parametric approximation of temporal evolutions with some thermal models

Artificial Intelligence (Neural Networks) – proper training of a network allows image enhancement
and defect characterization

Principal Component Analysis – the statistical technique that enables discrimination between significant
and insignificant image components

Data Fusion – combining Thermal NDT results with the data obtained by other NDT techniques, e.g.
ultrasonics, shearography etc.
3-7
Defects on Aircraft: Corrosion Detection
Exfoliation

Test area Pitting

Stringer

Аl
Heater Rivets
Aluminum
IR camera

Detected
Steel

Crack depth, mm

Missed
2

ThermoScopeTM 0 2,5 5, 7,5

Crack length, mm

Peculiarities:

• Powerful flash thermal stimulation required

• FPA snap-shot IR camera recommended
• “Black” painting advised
3-8 Graphite/Epoxy Composites

Phasegram (Fourier Rear surface IR

Impact damage transformation) thermogram

20x20 mm
Teflon inserts Thermal tomogram
location Depth 1.3 mm Depth 2.6 mm
(layer 1.2-1.9 mm)
Depth 4 mm
10x10 mm

Depth 2.6 mm
Depth 1.3 mm

Tomogram Tomogram
(layer 2.0-2.9 mm) (layer 4.0-4.8 mm)
3-9 Sophisticated Data Processing: Thermal Tomography

Inspection of the 5 mm-thick graphite epoxy composite

Optimal
Timegram
observation Maxigram
time

Defect depth 1.3 mm

Defect depth 2.6 mm
Timegram after reducing the noise
(notice the steep edges of defect
signals to compare with the
temperatutre signals)
 Jet Engine Turbine Blades (I)
3-10 Inspecting blocked passages
Turbine blade
Air, liquid
Surface Detected defects:
crack
• Blocked passages
• Wall thickness
Subsurface Front
crack
variations
• Surface and
subsurface cracks

Inspecting cracks

dT (x)
dx
dT (x)
View
dx
T (x) T (x)

Front Front

Boiling water
 Jet Engine Turbine Blades (II)
3-11

Non-defect blade, Blocked passage,

Source image source image

Non-defect blade, Blocked passage,

phasegram phasegram
3-12 Turbine Blade Coatings (III)
A A–A

0,14 mm
10 mm 0,18 mm
7 mm 0.5 mm 8 mm
D1 3 mm

Test
D2 5 mm
D4 80 mm
D3 A sample

Coating : Steel AISI 304 : Air:

l = 1 Вт/(м.K) l = 15 Вт/(м.K) l = 0,07 Вт/(м.K)
а = 4,35.10-7 м 2/с а = 3,75.10-6 м 2/с а = 5,8.10-5 м 2/с

Source IR image After computer treatment

 IR Thermographic Inspection of Airplanes
10-1
3-13 3

1
1

1
1

2
2
Inspecting Airplanes for Hidden Water

Airbus Industry and Boeing approved guidelines

3-14
Detecting Water in Aviation Glass Fiber Honeycombs

H2O: 6 g

X ray image

Thermogram
10-1
3-15
Detecting Water in Aviation Composite Honeycombs

Toupolev-204

Fuselage honeycombs

Eileron
15,7°C
15

10
SP01

Н20 0

Ilyushin-86 -4,4°C

0 Hz
9.3 °C

5
Ultrasonic test

-2.8 °C
3-16 Moisture Trapped in Porous Materials

Active technique:

Moisture detection and

quantitative evaluation

Thermogram of a single tile

Stored water
sites

Passive technique:

Moisture detection
 Sonic IR Imaging
3-17 (R. Thomas, L.D. Favro, Wayne State University, U.S.A.)
Ultrasonic Lock-in Thermography
(G. Busse, University of Stuttgart, Germany)
DT
Tnd DT

Tamb Tamb

УЗВ излучатель
Ultrasonic excitation

Impact Damage in Composites

Image Courtesy R. Thomas

3-18 Objects of Art: Detecting Detachments in Wall Fresco

Fogolino wall
fresco,
Bergamo, Italy

Detachment
Fresco plaster
5 mm
10 mm Arricio plaster
Source image
Support wall Mortar

9 mm Layer tomogram
3-19 Buried Land Mines (I)

Detecting mines from a Thermal image from a 200 m

helicopter (Bosnia, 2000) height shows plentiful clutter

Detecting mines on a noisy

background is a hard task
31,8°C
A US soldier tests a helmet-
30 mounted IR camera in
combination with a metal
25 detector and a ground
penetrating radar
Two 20

mines
15,6°C
3-20 Buried Land Mines (II)

Al

11:30

Paraffin

16:00

19:30
3-21 Early Diagnostics of Cancer

Healthy women’s breast is characterized by

a high level of thermal symmetry. The 3rd stage cancer of the left breast
cancer of the 1st stage creates temperature Temperature signal up to 5oC
signals 0.5-1.5oC 35,5°C

IR - I000 63 00 .0 62
3 4, 7 °C 34

34
32
33

30
32 SNR=3.45
SNR=0.064 31
28

30 27,6°C

2 9, 2
2 1.0 6.8 9 23 :33 :1 5
 Vladimir Vavilov
vavilov@introscopy.tpu.ru