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HYTEC’s Weld Forensics Systems (Non-Destructive Inspection tools and applications)
HYTEC builds systems and develops tools for conducting weld forensics, which means studies of welds and failures.
These tools are used primarily in three applications:
- Study of captured weapons and materials to determine their provenance
- Inspection of welds in manufactured parts, and
- Failure analysis when parts have failed.
For example, see Figure One. This is a part under test, titanium tube with welds at both ends. A .20 titanium penetrameter was imaged with the sample to demonstrate system resolution. The welds were imaged to demonstrate the capability of the system to inspect the weld quality. Sample analysis was performed using HYTEC’s FlashCT®. The system was equipped with a micro focus x-ray tube and an amorphous silicon digital detector. Geometric magnification of 5.33x was used for data acquisition.
Figure One. The image is taken from the raw data set originally acquired for 3D reconstruction. This image clearly shows the 3 quality indicator holes in the penetrameter.
Figure Two. This is a 3D reconstruction of the Figure One part, showing the weld flaw.
Figure Three. This is an end-on view, showing where the flaws are in respect to the inside surface of the sleeve.
All welders, even robotic welders, leave tell-tale marks which can help intelligence and/or law enforcement professionals to isolate the locus of manufacture/welding.
The manner of construction can be helpful in tracing the manufacturers as well.
The images in Figure Four show how internal parts can be exploded for study. In the firing pin we found molding marks, in the primary we found uneven surfaces caused by casting problems in formation of the igniting plunger, and in the weld joint between the pin itself and the impact ring a key give away – three weld points, denoting uneven heating and joining.
Figure Four (a), (b) and (c) –
from the upper right clockwise.
4(a) on the right shows the
mechanism and an enlargement
of the pin-plunger. 4(b) lower
right shows the highlighted
pin and its impact ring on the
top and the spring. 4(c), lower
left, shows the side view of the
pin, plunger, primary and the
outer casing of the element.
 
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