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Applied Physics

Design lifetimes for aerospace, power generation, petrochemical and other vital systems are fast approaching or have already been exceeded. Southwest Research Institute’s experienced staff is known worldwide for developing reliable, cost-effective nondestructive evaluation techniques to assure the integrity of aging infrastructures.

SwRI offers state-of-the-art rheology capabilities that characterize the flow properties of complex materials, such as adhesives, plastics, elastomers, paints and gels. SwRI has applied this expertise to programs seeking to understand crystallization kinetics, electro-rheological phenomena, slip behavior and more.

We are pioneers in magnetostrictive sensor technology, which continues to gain international prominence. We recently upgraded our latest system, the MsSR®3030, which uses acoustic guided waves to detect flaws in pipelines, steel cables, anchor rods, heat exchanger tubing and other metal structures. We significantly reduced the system’s size and weight, improved graphical user interfaces, and enhanced control and data acquisition capabilities.

Third-party contractors using digging or drilling equipment can unintentionally damage pipelines in their vicinity. For the Department of Energy, National Engineering Technology Laboratory, SwRI engineers are developing a new method to monitor pipelines for third-party contact. Monitoring signals are applied and sensed using existing cathodic protection test points, eliminating the need to unearth pipelines.

Our researchers use surface seismic reflection data to economically assess the presence and accessibility of water in a Florida aquifer. This image shows the inferred permeability (top) and porosity. A major flow unit is observed between 1,050–1,150 feet that corresponds to vuggy carbonate rock.

The riser pipes of deepwater platforms endure cyclic loading conditions as the platform sways with the varying ocean tides. We are independently evaluating new inspection processes to validate the inspection technology used to ensure that riser welds are free of defects that exceed riser construction code limits.

Corrosion fatigue is the principal cause of downtime in fossil power plants, significantly impacting operational costs. We are leading an Electric Power Research Institute project to develop ultrasonic technology to detect and size corrosion fatigue cracking in the water wall tubes of conventional boilers to help prevent catastrophic failure.

SwRI also develops nuclear power plant inspection technology, such as our EDAS® system, which is used to analyze ultrasonic and eddy current data collected from reactor pressure vessels to accurately locate, detect and size defects. This year, we improved the system’s graphical displays and added the capability to store and replay as a movie all of the operator’s actions.

The MsSR®3030 is the latest in our line of magnetostrictive sensor inspection systems for detecting defects in pipelines, steel cables, anchor rods, heat exchanger tubing and other metal structures. Our inspection systems are being used across the United States and in Japan, Korea, Indonesia, Venezuela, Mexico, Canada, Italy, Saudi Arabia and England.

We are evaluating a new approach that models how residual stress affects eddy current conductivity measured during an inspection. Although this effect is difficult to separate from other mechanical and operating characteristics, this model will be useful in predicting the remaining life of the component under inspection.

Regular inspections assure the flight-worthiness of aging T-37 aircraft, but the throttle cable is difficult to access and inspect. We developed a new ultrasonic inspection technique that requires access to one inch of the 9-foot-long cable, using ultrasonic guided waves that travel the length of the cable to detect flaws from this single access point.

In other aircraft integrity work, SwRI recently tore down C-5 and A-10 wings to find areas of fatigue and corrosion using eddy current, penetrant and visual inspection techniques. This information will help the Air Force extend the service life of these aircraft (nondestructive.swri.org).

Internal restrictions in pipelines prevent conventional inspection pigs from traveling through unimpeded. For the Department of Transportation, we are developing a remote-field eddy current system that collapses to move past obstructions, then expands to complete the inspection.

SwRI also develops advanced optical systems. Examples include compact, tunable lasers, ultrafast systems development for generating terahertz radiation and ultraviolet holography for precise nanometer-scale photolithography.

In the area of reservoir characterization, SwRI researchers applied a surface seismic reflection technique to gather data about a proposed aquifer storage and recovery area. Integrating this technique with well logging and other geological technology provides a practical and economical way to assess the presence and accessibility of water. 

Visit applied-physics.swri.org for more information or contact Vice President Ed Moore at (210) 522-2739 or emoore@swri.org.

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