This paper describes the development of an ultrasonic non-destructive examination (NDE) system that is incorporated into an automatic butt fusion welding machine and performs an examination of the joint within the cooling time of the welding cycle. The programme of work included the optimisation of the ultrasonic NDE techniques; the determination of the limits of detection of the NDE system; the determination of critical defect sizes and contamination levels in polyethylene (PE) pipe butt fusion welds; and the design and manufacture of a prototype machine capable of accommodating pipes between 125mm and 315mm outside diameter (OD).
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