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Microwave and millimetre-wave non-destructive testing and evaluation (NDT&E) has a long history dating back to the late 1950s (Bahr 1982 Microwave non-destructive testing methods ; Zoughi 2000 Microwave Non-destructive testing and evaluation principles ; Feinstein 1967 Surface crack detection by microwave methods ; Ash 1973 In 3rd European Microwave Conference ; Auld 1981 Phys. Technol. 12 , 149–154; Case 2017 Mater. Eval. 75 ). However, sustained activities in this field date back to the early 1980s (Zoughi 1995 Res. Nondestr. Eval. 7 , 71–74; Zoughi 2018 Mater. Eval. 76 , 1051–1057; Kharkovsky 2007 IEEE Instrumentation & Measurement Magazine 10 , 26–38). Owing to various limitations associated with using microwaves and millimetre waves for NDT&E, these techniques did not see much utility in the early days. However, with the advent and prevalence of composite materials and structures, in a wide range of applications, and technological advances in high-frequency component design and availability, these techniques are no longer considered as ‘emerging techniques’ (Zoughi 2018 Mater. Eval. 76 , 1051–1057; Schull 2002 Nondestructive evaluation: theory, techniques, and applications ). Currently, microwave and millimetre-wave NDT&E is a rapidly growing field and has been more widely acknowledged and accepted by practitioners over the last 25+ years (Case 2017 Mater. Eval. 75 ; Bakhtiari 1994 IEEE Trans. Microwave Theory Tech . 42 , 389–395; Bakhtiari 1993 Mater. Eval. 51 , 740–743; Bakhtiari 1993 IEEE Trans. Instrum. Meas. 42 , 19–24; Ganchev 1995 IEEE Trans. Instrum. Meas. 44 , 326–328; Bois 1999 IEEE Trans. Instrum. Meas. 48 , 1131–1140; Ghasr 2009 IEEE Trans. Instrum. Meas. 58 , 1505–1513). Microwave non-destructive testing was recently recognized and designated by the American Society for Nondestructive Testing (ASNT) as a ‘Method’ on its own (Case 2017 Mater. Eval. 75 ). These techniques are well suited for materials characterization; layered composite inspection for thickness, disbond, delamination and corrosion under coatings; surface-breaking crack detection and evaluation; and cure-state monitoring in concrete and resin-rich composites, to name a few. This work reviews recent advances in four major areas of microwave and millimetre-wave NDT&E, namely materials characterization, surface crack detection, imaging and sensors. The techniques, principles and some of the applications in each of these areas are discussed. This article is part of the theme issue ‘Advanced electromagnetic non-destructive evaluation and smart monitoring’.

Pipelines play an important role in the national/international transportation of natural gas, petroleum products, and other energy resources. Pipelines are set up in different environments and consequently suffer various damage challenges, such as environmental electrochemical reaction, welding defects, and external force damage, etc. Defects like metal loss, pitting, and cracks destroy the pipeline’s integrity and cause serious safety issues. This should be prevented before it occurs to ensure the safe operation of the pipeline. In recent years, different non-destructive testing (NDT) methods have been developed for in-line pipeline inspection. These are magnetic flux leakage (MFL) testing, ultrasonic testing (UT), electromagnetic acoustic technology (EMAT), eddy current testing (EC). Single modality or different kinds of integrated NDT system named Pipeline Inspection Gauge (PIG) or un-piggable robotic inspection systems have been developed. Moreover, data management in conjunction with historic data for condition-based pipeline maintenance becomes important as well. In this study, various inspection methods in association with non-destructive testing are investigated. The state of the art of PIGs, un-piggable robots, as well as instrumental applications, are systematically compared. Furthermore, data models and management are utilized for defect quantification, classification, failure prediction and maintenance. Finally, the challenges, problems, and development trends of pipeline inspection as well as data management are derived and discussed.

Combinative methodologies have the potential to address the drawbacks of unimodal non-destructive testing and evaluation (NDT & E) when inspecting multilayer structures. The aim of this study is to investigate the integration of information gathered via phased-array ultrasonic testing (PAUT) and pulsed thermography (PT), addressing the challenges posed by surface-level anomalies in PAUT and the limited deep penetration in PT. A center-of-mass-based registration method was proposed to align shapeless inspection results in consecutive insertions. Subsequently, the aligned inspection images were merged using complementary techniques, including maximum, weighted-averaging, depth-driven combination (DDC), and wavelet decomposition. The results indicated that although individual inspections may have lower mean absolute error (MAE) ratings than fused images, the use of complementary fusion improved defect identification in the total number of detections across numerous layers of the structure. Detection errors are analyzed, and a tendency to overestimate defect sizes is revealed with individual inspection methods. This study concludes that complementary fusion provides a more comprehensive understanding of overall defect detection throughout the thickness, highlighting the importance of leveraging multiple modalities for improved inspection outcomes in structural analysis.

There is a strong demand in the oil and gas industry to develop alternatives to manual inspection. This paper presents AeroX, a novel aerial robotic manipulator that provides physical contact inspection with unprecedented capabilities. AeroX has a semi-autonomous operation, which provides interesting advantages in contact inspection. In the free-flight mode, the pilot guides the robot until performing contact with its end-effector on the surface to be inspected. During contact, AeroX is in its fully-autonomous global navigation satellite system (GNSS)-free contact–flight mode, in which the robot keeps its relative position w.r.t. the surface contact point using only its internal sensors. During autonomous flight, the inspector can move—with uninterrupted contact—the end-effector on the surface for accurately selecting the points where to perform A-scan measurements or continuous B-scan or C-scan inspections. AeroX adopts an eight-tilted rotor configuration and a simple and efficient design, which provides high stability, maneuverability, and robustness to rotor failure. It can perform contact inspection on surfaces at any orientation, including vertical, inclined, horizontal-top or horizontal-bottom, and its operation can be easily integrated into current maintenance operations in many industries. It has been extensively validated in outdoor experiments including a refinery and has been awarded the EU Innovation Radar Prize 2017.

The growing population and increasing demand for surface transportation have highlighted the importance of maintaining safe and reliable civil infrastructures for daily use. Among all civil infrastructures, bridges are one of the most important elements in the transportation system. As such, to prevent any failures caused by aging and environmental impacts, bridges require periodic inspections. This becomes even more critical due to climate change and its effect on bridges, especially in the coastal regions. Most of the inspections conducted incorporate the visual type of evaluation due to its simplicity. However, with the current developments in new technologies, there is a need for more advanced techniques of structural health monitoring (SHM) methods to be incorporated in the maintenance programs for more accurate and efficient surveys. In this paper, non-destructive testing (NDT) methods applicable to steel bridges are reviewed, with a focus on methods applicable to local damage detection. Moreover, the methodology, advantages and disadvantages, and up-to-date research on NDT methods are presented. Furthermore, the application of novel NDT techniques using innovative sensors, drones, and robots for the rapid and efficient assessment of damages on small and large scales is emphasized. This study is deemed necessary as it compiles in one place the available information regarding NDT methods for in-service steel bridges. Access to such information is critical for researchers who intend to work on new or improved NDT techniques.

Since 2019, the Italian Association for Non-Destructive Testing has been collaborating with the International Atomic Energy Agency in the sector of development and certification of Non Destructive Testing and during the interventions for recovery after natural and non-natural disasters. In this context Italian experts have had the opportunity to take part to many international technical cooperation missions, at national and regional level, giving training about methods for structural assessment of damaged buildings and on the use of non-destructive testing aimed to analyze the integrity of buildings affected by disasters. These missions have often taken place in complex environmental conditions, due to the geopolitical situation of the areas, like in Beirut or Damascus. However, in any case, the contribution of Italian technicians has been relevant, particularly with reference to the approach to the buildings classified as cultural heritage. It has to be underlined that our national history and culture eases the knowledge transfer to different geographical contexts, and that Italian skills in this specific sector are relevant, as well as appreciated worldwide.

In this article, we survey various non-contact, non-destructive testing methods by way of terahertz (THz) spectroscopy and imaging designed for use in various industrial sectors. A brief overview of the working principles of THz spectroscopy and imaging is provided, followed by a survey of selected applications from three industries—the building and construction industry, the energy and power industry, and the manufacturing industry. Material characterization, thickness measurement, and defect/corrosion assessment are demonstrated through the examples presented. The article concludes with a discussion of novel spectroscopy and imaging devices and techniques that are expected to accelerate industry adoption of THz systems.

Microwave imaging and defectoscopy are promising techniques for dielectric composite evaluation. Their most significant advantage is their relatively high penetration depth. Another feature worth noting is that traditional methods could not acquire an internal content with such a low impact on both the sample and surrounding environment, including the test operator, compared to other techniques. This paper presents microwave non-destructive and noninvasive methods for quality evaluation of layered composite materials using an open-ended waveguide probe. Pure |S11| parameters only exceptionally give a clear answer about the location of material cracks. Therefore, this makes it necessary to analyze these parameters simultaneously along with several other factors, such as stand-off distance, probe type or wave polarization. The purpose of the work was to find the dependency between the physical state of a layered composite powerplant pipeline and the S-matrix parameters response (reflection and transmission parameters) in a Ku frequency band that has not yet been extensively researched. Lower-frequency measurements broaden the application possibility for thicker composites, mainly because of a higher penetration depth and measurement setup availability. Different methods have been shown, including reflection and transmission/reflection methods, both in close proximity and in stand-off distance. The measurements are based on a low-complexity experimental setup.

The need for non-destructive testing/structural health monitoring (SHM) is becoming increasingly important for gas turbine manufacturers. Incipient cracks have to be detected before catastrophic events occur. With respect to condition-based maintenance, the complex and expensive parts should be used as long as their performance or integrity is not compromised. In this study, the main failure modes of turbines are reported. In particular, we focus on the turbine blades, turbine vanes and the transition ducts of the combustion chambers. The existing monitoring techniques for these components, with their own particular advantages and disadvantages, are summarised in this review. In addition to the vibrational approach, tip timing technology is the most used technique for blade monitoring. Several sensor types are appropriate for the extreme conditions in a gas turbine, but besides tip timing, other technologies are also very promising for future NDT/SHM applications. For static parts, like turbine vanes and the transition ducts of the combustion chambers, different monitoring possibilities are identified and discussed.

Robust and lane-level positioning is essential for autonomous vehicles. As an irreplaceable sensor, Light detection and ranging (LiDAR) can provide continuous and high-frequency pose estimation by means of mapping, on condition that enough environment features are available. The error of mapping can accumulate over time. Therefore, LiDAR is usually integrated with other sensors. In diverse urban scenarios, the environment feature availability relies heavily on the traffic (moving and static objects) and the degree of urbanization. Common LiDAR-based simultaneous localization and mapping (SLAM) demonstrations tend to be studied in light traffic and less urbanized area. However, its performance can be severely challenged in deep urbanized cities, such as Hong Kong, Tokyo, and New York with dense traffic and tall buildings. This paper proposes to analyze the performance of standalone NDT-based graph SLAM and its reliability estimation in diverse urban scenarios to further evaluate the relationship between the performance of LiDAR-based SLAM and scenario conditions. The normal distribution transform (NDT) is employed to calculate the transformation between frames of point clouds. Then, the LiDAR odometry is performed based on the calculated continuous transformation. The state-of-the-art graph-based optimization is used to integrate the LiDAR odometry measurements to implement optimization. The 3D building models are generated and the definition of the degree of urbanization based on Skyplot is proposed. Experiments are implemented in different scenarios with different degrees of urbanization and traffic conditions. The results show that the performance of the LiDAR-based SLAM using NDT is strongly related to the traffic condition and degree of urbanization. The best performance is achieved in the sparse area with normal traffic and the worse performance is obtained in dense urban area with 3D positioning error (summation of horizontal and vertical) gradients of 0.024 m/s and 0.189 m/s, respectively. The analyzed results can be a comprehensive benchmark for evaluating the performance of standalone NDT-based graph SLAM in diverse scenarios which is significant for multi-sensor fusion of autonomous vehicle.