Nondestructive Testing Simulator

Non-destructive testing (NDT) is essential for evaluating the durability and integrity of components without causing damage, such as inspecting water pipes in nuclear energy facilities. Using ultrasonic testing (UT), inspectors can transmit and analyze ultrasonic waves to detect flaws in parts, including non-uniform thickness, cracks, or weld imperfections. To train and evaluate inspectors, a simulator was developed for Ooga Technologies. This simulator employed an inertial measurement unit (IMU) to track the position of a probe relative to a fixed specimen containing simulated faults. The data is processed in real time through an algorithm that generates representative ultrasonic waveforms for the user to interpret. The simulated faults can be adjusted in both position and number to provide diverse testing scenarios and prevent repetition or cheating between tests. The test fixture accommodated a wide range of parts and included a calibration process allowing users to fine-tune their output waveforms. The simulator operated successfully, though several unanticipated limitations were observed during testing.