Infrared in the Automotive Industry
Roy Huff, ASNT NDT Level III
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 In recent years the use of thermography for nondestructive testing has made tremendous advances. The latest involves what is called Flash Thermography. In Flash Thermography where a part is heated and then allows for advanced analysis techniques. Reconstructing the thermal data is a process where the raw temporal response from each pixel is reconstructed into a mathematical function (Shepard et al., 2002). Not only is system noise reduced, but a variety of analysis techniques become possible, improving the ability to resolve deeper and more subtle subsurface features. Here we see a disbond on a Corvette’s halo is revealed with Flash Thermography, a defect that would otherwise go unnoticed without this advanced testing. |
| These are but a few samples of some of the great work being done within the automotive industry. The Snell Group has been fortunate to be involved with training and consulting in all aspects of the industry. We hope to see the recent increases in car sales, as compared to a year ago, and the investment in strong thermography programs, continue go hand in hand. |
Our fascination with various means of transportation lends itself nicely to the world of thermography. Robust thermography programs are instrumental parts of reliability programs at automotive assembly plants throughout the world. Research and development (R&D) and non-destructive testing (NDT) applications that use IR are a significant part of the design process while infrared thermography for electrical and mechanical reliability applications is widely used by facility maintenance teams over in assembly. In the image to the left we see a resistance connection on a breaker in a control cabinet.
New cars and concept vehicles are put through an amazing amount of thermal testing prior to release. One aspect where thermography plays a role is in passenger safety and comfort. Proper placement of insulation or reflectors in the floor pan can prevent “hot foot” for drivers and passengers. Thermal confirmation of insulation in the unibody structure can also increase passenger comfort and reduce noise levels, such as this IR image, to the right, showing foam fill insulation in the unibody.
Heated seat testing allows for maximum passenger comfort without the possibility of a painful burn. In the image to the left, you can see how thermal imaging can be used to measure temperatures on the surface of the seat to ensure that a certain threshold is not exceeded.
Evaluation of operating temperatures can play a role to ensure there is adequate cooling. Convection plays a key role in cooling. Whether by proper sizing of coolant reservoirs and radiators or appropriate air flow on cooling fins on motorcycles, keeping those engines cool is paramount and is another place where thermal imaging can help as seen with this V-Twin on a Harley Davidson, left.