Pulsed eddy current stimulated thermography is a novel non-destructive evaluation (NDE) technique that employs an infrared camera to detect defects, typically cracks at the surface of a component, by imaging the effects that they have on the heating of a component produced by a pulsed eddy current heating system. To date, eddy currents in the 50-200 kHz range have been generated in a test-piece using a conventional eddy current heating system with a simple, two or three turn, encircling coil. Cracks block the flow of eddy currents and significantly alter current flow lines in their vicinity. The Joule heating caused by the eddy currents can be imaged by an infrared camera, providing a means of detecting cracks by imaging the characteristic effects that they have on eddy current distribution. The method is considerably quicker than conventional ultrasonic or eddy current inspection techniques that require point by point scanning. Whilst impressive results have been achieved in a small number of laboratories, the system, particularly the excitation, needs engineering. The reliability of the system needs to be investigated as there is concern that defects in some locations on a component may be missed; this is a function of the eddy current density that is generated across the surface of a component by the excitation system. In addition, results to date are rather qualitative with little indication of defect detectability or its dependence on system, defect or test-piece parameters. This proposal is for a scientific investigation of the eddy current excitation requirements for a reliable eddy current stimulated thermography inspection system and measurements to determine the defect detection capabilities of such a system. The plan is for a two person-year project in which the first year will be based at Newcastle with the work focussed on the modelling of the requirements of the eddy current excitation system and on researching the design and construction of a suitable system. The second year will be based at Bath where the system will be used to research defect detection capabilities. Two types of excitation system will be investigated. One for the testing of small components that can be placed within an encircling coil and the other for the testing of larger components which will be progressively tested using a coil to produce heating in a localised region of the component. Practical specimens will be provided by the industrial collaborators, Rolls-Royce and Astom Power. The project will involve in-depth modelling of the eddy current density induced in the surface of a specimen and its heating effect at cracks of different size set at different orientations and locations across the component. The effects of changing the orientation of a specimen within the eddy current coil will be modelled to establish inspection measurements that should lead to the detection of defects set at all orientations within the specimen. Experimental studies will be made of the performance of the system in detecting and imaging defects of different sizes, shapes and orientation. The performance of the technique will be compared with the other thermographic NDE methodologies: optical stimulated, conventional transient thermography and acoustically-stimulated thermosonics. The overall aim of the project is to perform a thorough scientific investigation of a promising new NDE technique that is needed before the technique can be introduced successfully into industry.

In many cases failure mechanisms initiate and propagate from the surface, including failure under corrosion, fatigue and wear. Critical to this is the surface finish (SF) and the surface integrity (SI). While surface finish has received much attention, surface integrity, a term used to describe the localised sub-surface region that differs from the bulk (residual stresses, plastic deformation, chemical changes, hardness, etc) has received much less attention. Traditionally people have used simple cross sections to examine the surface microstructure.In this project we will apply a suite of state-of-the-art methods to characterise as fully as possible the local microstructure in 3D across a range of scales. These include serial sectioning using a focused ion beam (FIB), mechanical sectioning and X-ray tomography. In the latter X-rays are used to obtain a 3D picture without mechanically sectioning the sample. Critical to the former methods are the means of removing material quickly and efficiently without introducing damage. Emerging methods to remove the damaged layer will be developed such that we can obtain EBSD, texture, chemical mapping, residual stress and insights into plastic deformation near-surface. This will lead to one of the best surface integrity assessment facilities in the world to support industry. In addition we will develop micromechanical methods to assess mechanical properties and corrosion and wear performance. In this way we will relate surface integrity to surface durability. This is critical if we are to predict and engineer surface performance. In addition to developing these metrology tools we will apply them to a set of industrial case studies including corrosion of stainless steel for the energy sector, the performance of thermal barrier coatings for the turbine engine sector, the wear performances of WC-Co coatings and nanostructured coatings. Further case studies will be identified by our industrial steering group.

Biomass - vegetation such as trees, grasses or straws - is resurging as a source of sustainable, environmentally-friendly fuel for use in power stations. This is because, when grown in a sustainable way, it is almost carbon-neutral - the carbon-doxide emitted when the biomass is burned, is readsorbed from the atmosphere during the photosynthesis of the next crop of biomass. Consequently, there is a great deal of interest in using biomass in coal-fired power stations by substituting a portion of the coal. Today, many power-stations in the UK have adopted this co-firing approach to reduce their carbon (dioxide) emissions. This is a good strategy since the biomass is burned in the very large coal power stations which have a higher efficiency than the small systems needed if the same amount of biomass was to be burned alone. However, in the power stations the coal is crushed to a fine powder in huge mills before being blown into the burners in the boiler. Most biomass does not grind or crush very well because it is springy and fibrous. Consequently, when power generators attempt to powder the biomass in the coal mills it tends to form a mat on the bottom of the mill. This has limited the amount of biomass which can be processed in the mills and hence limited the amount of biomass used in the power-stations, and hence limited the carbon savings from co-firing biomass. Some power stations have invested millions of pounds to install separate, different types of mills for cutting biomass so that they can use more - for example, up to 20% by weight is used in Fiddlers Ferry power station. Another strategy is a process known as torrefaction in which the biomass is pre-treated so that it becomes more brittle and easier to crush. This process involves heating biomass to a moderate temperature (~280 C) in the absence of air. It is similar to the process used to roast coffee beans and so is sometimes refered to as roasting biomass. During torrefaction some material is lost from the biomass - particularly moisture and some gases and volatile substances - but the material which is left, the residue, still contains typically 80% of the heating value of the original biomass, and is transformed into a harder, darker fuel, which is much easier to crush. This process is attracting a great deal of interest from all sectors involved in the bioenergy chain: - growers see this is a way of adding value to the biomass they grow and reducing transportation costs (since the fuel is dry and has a greater energy per unit volume); power-generators see this as a simpler fuel to handle in the power stations; and there is also interest in using torrefied biomass as a fuel in other conversion processes, such as biomass gasification to liquid (transport) fuels (BTL). Furthermore, torrefied biomass does not go mouldy upon storage like raw biomass and so it becomes attractive for extending the supply window for using biomass. In order for torrefaction of biomass to happen on a large scale much information is needed in order to design safe, environmentally-friendly torrefiers. This research is aimed at providing much of this information and answering these questions: What are the explosion risks within torrefiers or mills using torrefied biomass? (Fine dust can result in explosions under certain concentrations, and knowledge of these concentrations is needed in order to incorporate adequate safety design features.) What would the effluents from the process (liquid and gas) be composed of? Can the gas and vapours produced provide the heat to drive the torrefaction? How would torrefied biomass burn in the power station? It also aims to develop a tool which engineers can use to help them design the torrefier itself, so that they know what temperature is needed, and how long the biomass needs to reside within the torrefier so that an optimum fuel is produced.

Pulsed eddy current stimulated thermography is a novel non-destructive evaluation (NDE) technique that employs an infrared camera to detect defects, typically cracks at the surface of a component, by imaging the effects that they have on the heating of a component produced by a pulsed eddy current heating system. To date, eddy currents in the 50-200 kHz range have been generated in a test-piece using a conventional eddy current heating system with a simple, two or three turn, encircling coil. Cracks block the flow of eddy currents and significantly alter current flow lines in their vicinity. The Joule heating caused by the eddy currents can be imaged by an infrared camera, providing a means of detecting cracks by imaging the characteristic effects that they have on eddy current distribution. The method is considerably quicker than conventional ultrasonic or eddy current inspection techniques that require point by point scanning. Whilst impressive results have been achieved in a small number of laboratories, the system, particularly the excitation, needs engineering. The reliability of the system needs to be investigated as there is concern that defects in some locations on a component may be missed; this is a function of the eddy current density that is generated across the surface of a component by the excitation system. In addition, results to date are rather qualitative with little indication of defect detectability or its dependence on system, defect or test-piece parameters. This proposal is for a scientific investigation of the eddy current excitation requirements for a reliable eddy current stimulated thermography inspection system and measurements to determine the defect detection capabilities of such a system. The plan is for a two person-year project in which the first year will be based at Newcastle with the work focussed on the modelling of the requirements of the eddy current excitation system and on researching the design and construction of a suitable system. The second year will be based at Bath where the system will be used to research defect detection capabilities. Two types of excitation system will be investigated. One for the testing of small components that can be placed within an encircling coil and the other for the testing of larger components which will be progressively tested using a coil to produce heating in a localised region of the component. Practical specimens will be provided by the industrial collaborators, Rolls-Royce and Astom Power. The project will involve in-depth modelling of the eddy current density induced in the surface of a specimen and its heating effect at cracks of different size set at different orientations and locations across the component. The effects of changing the orientation of a specimen within the eddy current coil will be modelled to establish inspection measurements that should lead to the detection of defects set at all orientations within the specimen. Experimental studies will be made of the performance of the system in detecting and imaging defects of different sizes, shapes and orientation. The performance of the technique will be compared with the other thermographic NDE methodologies: optical stimulated, conventional transient thermography and acoustically-stimulated thermosonics. The overall aim of the project is to perform a thorough scientific investigation of a promising new NDE technique that is needed before the technique can be introduced successfully into industry.

This project seeks to investigate the potential for using waste materials within combustion systems within the UK in the future, and how the combustion of such wastes might affect the ability of a power station to respond to changes in electricity demand. The purpose is not to look at today's electricity system and systems of governance with respect to combustion of wastes, but to consider how a rational system would be designed that utilised all potential fuel streams (and takes into account that different wastes will contain different levels of trace elements, some of which may be quite minor). An important point is that many wastes are currently landfilled - meaning that both the energy content of the waste is lost and a bulky material ends up in landfill. Here, we will conduct experiments looking at emissions of trace elements during combustion and co-firing (with coal) of different types of "waste" materials (for example, wood from demolition sites), together with analysis of ashes produced. The results will then be used to generate models of power plants burning wastes, and used to determine whether, for the wastes examined, the most rational use of the waste is combustion in dedicated facilities or co-combustion. It is clear that some of the wastes we will examine currently fall within the remit of the waste incineration directive (though all will be non-halogenated). We will examine whether this is scientifically valid.