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The Scaled Boundary Finite Element Method (SBFEM) is a semi-analytical method that showed promising results in modelling of guided ultrasonic waves. Efficiency and a low computational cost of the method are achieved by the discretisation of the boundary of a computational domain only, whereas for the domain itself the analytical solution is used. By means of the SBFEM different types of defects, e.g. fatigue cracks, pores, delamination, corrosion, integrated into a structure consisting of anisotropic and isotropic materials can be modelled.
In this contribution, the SBFEM is used to analyse the propagation of guided waves in a structure consisting of an isotropic metal bonded to anisotropic carbon fibre reinforced material. The method allowed to identify appropriate wave types (modes) and to analyse their interaction with different defects. Obtained results will be used to develop a structural health monitoring system for composite pressure vessels used in automotive industry.
Distributed Fibre Optic Sensing for Monitoring and Testing of Industrial and Civil Infrastructures
(2018)
Fibre optic sensors enable the gathering of sensory information in environments where conventional sensors fail or simply can not be utilised. Their small size enables their use in confined spaces as well as their embedding or integration in components, structures or composite materials while offering, depending on the approach, high sensitivity, very high spatial resolution and, especially, the possibility to detect or measure physical quantities in a distributed way, meaning spatially continuous sensing over very long distances.
Those distributed fibre optic sensors (DFOS) provide access to sensing information from different locations along the sensing fibre without the need for technologically challenging multiplexing of many point sensors and the subsequent sensor data fusion. In this way, DFOS are excellently suited as smart sensors for monitoring or testing purposes as the spatially distributed sensing data make available spatially resolved measurand profiles without a gap. Furthermore, the possible embedding or integration of DFOS could facilitate the development of smart structures or smart components. In particular distributed vibration sensing (DVS) and distributed temperature sensing (DTS) are also ideally suited for condition monitoring of machinery, industrial installations or extensive infrastructure, also, on-line real-time assembly or component testing in production lines, e.g. for quality control, is possible.
In this talk, we will shortly outline the underlying principles of some fibre optic sensing approaches, explain their fundamental differences in mode of operation and performance, and discuss their applicability and limitations. Moreover, we will report on a subset of current and previous applied research projects at BAM, investigating different areas of use for distributed fibre optic sensors in particular.
We demonstrate ultrafast soliton-based nonlinear balancing of dual-core asymmetry in highly nonlinear photonic crystal fiber at sub-nanojoule pulse energy level. The effect of fiber asymmetry was studied experimentally by selective excitation and monitoring of individual fiber cores at different wavelengths between 1500 nm and 1800 nm. Higher energy transfer rate to non-excited core was observed in the case of fast core excitation due to nonlinear asymmetry balancing of temporal solitons, which was confirmed by the dedicated numerical simulations based on the coupled generalized nonlinear Schrödinger equations. Moreover, the simulation results correspond qualitatively with the experimentally acquired dependences of the output dual-core extinction Ratio on excitation energy and wavelength. In the case of 1800 nm fast core excitation, narrow band spectral intensity switching between the output channels was registered with contrast of 23 dB. The switching was achieved by the change of the excitation pulse energy in sub-nanojoule region. The performed detailed analysis of the nonlinear balancing of dual-core asymmetry in solitonic propagation regime opens new perspectives for the development of ultrafast nonlinear all-optical switching devices.
High-Amplitude Surge of a Pitching Airfoil: Complementary Wind- and Water-Tunnel Measurements
(2018)
RECENT interest in gust response, rotorcraft forward flight and wind energy, among other applications, has focused on streamwise oscillations of nominally two-dimensional airfoils in attached and separated flows. The airfoil may be simultaneously held at constant incidence or execute some maneuver, such as pitch.
The relative freestream is spatially uniform but temporally unsteady, and this can be accomplished in a ground-test facility in two ways. The first method is to vary the output of the prime mover, such as the rotational speed of the impeller or the blower driving a wind tunnel, or (alternatively) to vary the pressure drop in the tunnel, thereby varying the flow speed in the test section, despite nominally constant primemover revolutions per minute. The second method is used to keep the tunnel’s operating speed constant, as well as to move the test article in the streamwise direction, fore and aft (for example, via an electric linear motor), such that the relative freestream speed felt by the test article varies according to some waveform. Typically, the latter approach is chosen in water tunnels, where there is too much tunnel-circuit inertia to vary the flow speed directly but where the usually low tunnel test section flow speeds enable large excursions in the relative freestream by oscillation of the test article. In fact, outright reverse flow is possible by moving the test article in the laboratory frame at a higher speed than the water-tunnel flow speed. In either case, a sinusoidal relative-speed waveform is the most intuitively realizable, and this can be combined with similar oscillations in the airfoil incidence angle or other kinematics. Although the two methods of realizing streamwise oscillations are mechanically distinct, experimental comparisons between an oscillating test article in a water tunnel and a stationary test article in a wind tunnel with a louvermechanismhave demonstrated agreement in themeasured lift and drag histories. Such experimentswere performed by Granlund et al. for a 10% freestream amplitude oscillation and fixed airfoil incidence, comparing a free-surface water tunnel and a closed-circuit wind tunnel. After buoyancy was subtracted from the wind-tunnel data (resulting from the louver pressure drop) and the model inertia subtracted from the water-tunnel data (resulting from acceleration of the test article), the remaining lift and drag histories matched well at the low freestream oscillation amplitude regime. The work of Granlund et al. was later extended to high-advance-ratio streamwise oscillations of 50% amplitude by Greenblatt et al., where the aerodynamic histories of the water-tunnel and wind-tunnel facilities were compared in combined pitch and freestreamoscillations (governed by relative pitch phase), pure pitch oscillations, and purely freestream oscillations. Agreement between the two facilities’ data for fixed-incidence streamwise oscillations was reasonably good, and in fact, better than agreement in just the static lift and drag, evidently owing to differences in blockage and model-support systems. Additionally, Greenblatt et al. determined there was no strong coupling between simultaneous freestream oscillations and pitch oscillations on resultant lift and moment coefficients.
The in situ analysis of the damage evolution in a metal Matrix composite (MMC) using synchrotron X-ray refraction radiography (SXRR) is presented. The investigated material is an Al alloy (6061)/10 vol% Al2O3 MMC after T6 heat treatment.
In an interrupted tensile test the gauge section of dog bone-shaped specimens is imaged in different states of tensile loading. On the basis of the SXRR images, the relative change of the specific surface (proportional to the amount of damage) in the course of tensile loading was analyzed. It could be shown that the damage can be detected by SXRR already at a stage of tensile loading, in which no Observation of damage is possible with radiographic absorption-based imaging methods.
Moreover, the quantitative analysis of the SXRR images reveals that the amount of damage increases homogeneously by an average of 25% with respect to the Initial state. To corroborate the experimental findings, the damage distribution was imaged in 3D after the final tensile loading by synchrotron X-ray refraction computed tomography (SXRCT) and absorption-based synchrotron X-ray computed tomography (SXCT). It could be evidenced that defects and damages cause pronounced indications in the SXRCT images.
Industrial Radiology is used for volumetric inspection of industrial objects. By penetration of these objects (typically weldments, pipes or castings) with X-ray or Gamma radiation the 3D-volume is projected onto a 2D image detector. The X-ray film is the oldest radiographic image detector and still in wide use in industry. The industrial X-ray film systems used today differ from these used in medicine. Medical film systems are described well in the literature, but industrial film systems not. So we start with a description of the properties and standards for industrial film systems. The requirements on image quality are defined by several standards and can be verified with different image quality indicators (IQIs). They describe the ability of the human being to detect small and low contrast indications in a noisy image background. The essential parameters for digital industrial radiology are described.
Since about 30 years electronic image detectors are gradually replacing the industrial film. These detectors are based on storage phosphor imaging plates in combination with Laser scanners (“Computed Radiography”, CR) or a variety of different digital detector arrays (DDA). Typical applications of CR and DDAs are discussed as well as new possibilities by digital image processing, which is enabled by the computer based image handling, processing and analysis.
Microstructural changes in porous cordierite for diesel particulate filter applications caused by machining were characterized using microtensile testing and X-ray computed tomography (XCT). Young’s modulus was determined on ~215-380 m thick machined samples by digital image correlation. Results show a decrease of Young’s modulus due to machining of the thin samples. Explanation of this phenomenon was provided by XCT: the presence of debris due to machining and the variation of porosity due to removal of the outer layers were quantified and correlated with the introduction of further microcracking.
The present work offers an explanation for the variation of the power-law stress exponent, n, with the stress r normalized to the shear modulus G in aluminum alloys. The approach is based on the assumption that the dislocation structure generated with deformation has a fractal nature. It fully explains the evolution of n with r/G even beyond the so-called power law breakdown region. Creep data from commercially pure Al99.8%, Al-3.85%Mg, and ingot AA6061 alloy tested at different temperatures and stresses are used to validate the proposed ideas. Finally, it is also shown that the fractal description of the dislocation structure agrees well with current knowledge.
Defect recognition in CFRP components using various NDT methods within a smart manufacturing process
(2018)
The manufacturing process of carbon fiber reinforced polymer (CFRP) components is gaining a more and more significant role when looking at the increasing amount of CFRPs used in industries today. The monitoring of the manufacturing process and hence the reliability of the manufactured products, is one of the major challenges we need to face in the near future. Common defects which arise during manufacturing process are e.g. porosity and voids which may lead to delaminations during operation and under load. To find irregularities and classify them as possible defects in an early stage of the manufacturing process is of high importance for the safety and reliability of the finished products, as well as of significant impact from an economical point of view. In this study we compare various NDT methods which were applied to similar CFRP laminate samples in order to detect and characterize regions of defective volume. Besides ultrasound, thermography and eddy current, different X-ray methods like radiography, laminography and computed tomography are used to investigate the samples. These methods are compared with the intention to evaluate their capability to reliably detect and characterize defective volume. Beyond the detection and evaluation of defects, we also investigate possibilities to combine various NDT methods within a smart manufacturing process in which the decision which method shall be applied is inherent within the process. Is it possible to design an in-line or at-line testing process which can recognize defects reliably and reduce testing time and costs? This study aims to show up opportunities of designing a smart NDT process synchronized to the production based on the concepts of smart production (Industry 4.0). A set of defective CFRP laminate samples and different NDT methods were used to demonstrate how effective defects are recognized and how communication between interconnected NDT sensors and the manufacturing process could be organized.
Distributed vibration sensing in optical fibers opened entirely new opportunities and penetrated various sectors from security to seismic monitoring. Here, we demonstrate a most simple and robust approach for dynamic strain measurement using wavelength-scanning coherent optical time domain reflectometry (C-OTDR). Our method is based on laser current modulation and Rayleigh backscatter shift correlation. As opposed to common single-wavelength phase demodulation techniques, also the algebraic sign of the strain change is retrieved. This is crucial for the intended applications in structural health monitoring and modal analysis. A linear strain response down to 47.5 pε and strain noise of 100 pε/√Hz is demonstrated for repetition rates in the kHz range. A field application of a vibrating bridge is presented. Our approach provides a cost-effective high-resolution method for structural vibration analysis and geophysical applications.