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Calculation of ultrasonic reflection and transmission in anisotropic austenitic layered structures
(1999)
The successive fatigue failure process, i.e. crack initiation and growth up to electrical failure, has been investigated for a flip chip configuration. A cracked and uncracked solder bump was analysed using an unified viscoplastic constitutive model (Chaboche). The electrical failure of a bump seems to be reached in general not before a deep crack has grown into the bump. In order to update the actual loading situation two different cracked structures were calculated.
The last 25 years have seen an explosion in the number of new x-ray based imaging methods and applications. In reviewing these new capabilities we see that the ability to generate improved data quality underlies a number of the major advances. Improvement in the quality of x-ray sources, in detector resolution and dynamic range, in data analysis methods both in image processing and in reconstruction techniques have yielded significant advances in image quality. In addition to the improved imaging hardware, the use of computers play a key role in extending capabilities in high speed computed tomography, in real time image enhancement, in automated defect recognition and in the development of accurate x-ray inspection simulations. The ability to generate information and to analyze the complexities introduced by typical inspection demands can quickly outstrip even today's computational resources. Developments in parallel computing and computer memory are beginning to managing the huge data volumes now routinely produced and open up a number of new applications. Some examples include high-resolution 3D-image generation with the capability to probe micron length scales, dual energy computed tomography providing improved airport security, materials characterization techniques providing new tool for process development, and x-ray image formation modeling. The ability to model the details of the generation of bremsstrahlung radiation and its interaction with the complex geometry of the object under consideration provide for the first time a means to determine and quantify the optimal parameters for an inspection. These advances over the last 25 years represent exciting time in x-ray imaging, the impact of which will be played out in the next decade. ©2001 American Institute of Physics.
The market of the penetrant systems is increasing every year. A sensitivity of the penetrant systems is one of the main criteria for a customer. Therefore the importance of reliable result of the determination of penetrant systems sensitivity is increasing as well. It was established in our experiments that repeating the procedure of type testing in accordance with ISO EN 3452-2, in many cases one can obtain rather variable results for the sensitivity level. The goal of our investigations was to establish the principal factors, influencing upon the result of penetrant system type testing. Our results show that the values of the duration of such penetrant inspection technological stages as penetrant and developer applications may be considerably lower than the values recommended by ISO EN 3452-2 for the type testing. At the same time the character of the procedure's realisation of excess penetrant removal and developer application strongly influences upon the type testing results. Some recommendations for obtaining more reliable results of the determination of penetrant system sensitivity are worked out and proposed. ©2002 American Institute of Physics.
Standard radiography simulators are based on the attenuation law complemented by built-up-factors (BUF) to describe the interaction of radiation with material. The assumption of BUF implies that scattered radiation reduces only the contrast in radiographic images but does not image object structures itself. This simplification holds for a wide range of applications like weld inspection as known from practical experience. But only a detailed description of the different underlying interaction mechanisms is capable to explain effects like mottling or others that every radiographer has experienced in practice. The application of the N-Particle Monte Carlo code MCNP is capable to handle primary and secondary interaction mechanisms contributing to the image formation process like photon interactions (absorption, incoherent and coherent scattering including electron-binding effects, pair production) and electron interactions (electron tracing including X-Ray fluorescence and Bremsstrahlung production). Additionally it opens up possibilities like the separation of influencing factors and the understanding of the functioning of intensifying screen used in film radiography. The paper intends to discuss the opportunities in applying the Monte Carlo method to investigate special features in radiography in terms of selected examples. It is important to note that the use of Monte Carlo methods is a laboratory type of technique for basic investigations because of the enormous computing power that is needed. For in-field applications such as for inspection planing simplified models are of much greater importance and increasingly in use. ©2003 American Institute of Physics
The paper presents a special reconstruction algorithm that is capable to monitor density differences in multi-phase flows. The flow cross section is represented as discrete dynamic random field. A fixed gray value is assigned to each flow phase characterizing the material property of the phase. The image model is given by a set of non-linear stochastic difference equations. The corresponding inversion task is not accessible by common tomographic techniques applying reconstruction algorithms like filtered backprojection or algebraic reconstruction technique (ART). The developed algorithm is based on the Kalman filter technique adapted to non-linear phenomena. The average velocity distribution together with the corresponding covariance matrix of the liquid flow through a pipe serves as prior information in statistical sense. To overcome the non-linearity in the process model as well as in the measurement model the statistical linearization technique is applied. Moreover the Riccati equation, giving the error covariance matrix, and the equation for the optimal gain coefficients can be solved in advance and later used in the filter equation. It turns out that the resulting reconstruction or filter algorithm is recursive, i.e. yielding the quasi-optimal solution to the formulated inverse problem at every reconstruction step by successively counting for the new information collected in the projections. The applicability of the developed algorithm is discussed in terms of characterizing or monitoring a multi-phase flow in a pipe. ©2003 American Institute of Physics
Degradation effects of automotive coatings after weathering as detected by thermoluminescence
(2004)
Laser vibrometric contactless sound field measurements at a concrete test block are presented. Both excitation by an ultrasonic probe and by an impactor were used. The wave modes can be identified by their geometric wave forms and propagation velocities. Additionally, numerical simulation of the experimental situation is used to support this interpretation. Possible applications of the presented technique are discussed. ©2005 American Institute of Physics
In this article we present inelastic neutron scattering (INS) experiments on different systems of confined glass-formers. The aim of these experiments is to study the influence of spatial restriction on the microscopic dynamics related to the glass transition. Such results could be helpful for the detection of a currently speculated cooperativity length of the glass transition. The glass-forming component is either a molecular liquid or a polymer. The confining matrices are `hard' (silica glass, silicon) or `soft' (microemulsion droplets). For some experiments the confining structure could be spatially oriented. Except for the soft confinement the naïvely expected acceleration effect could only be found at low temperatures where INS experiments are difficult because of the long relaxation times. A clear effect of confinement could be observed for the glass-typical low energy vibrations (boson peak). This effect seems to be completely different for soft and hard confinement. Surprisingly, the experiments on oriented nanopores did not show any signs of an anisotropy of the dynamics.
Ultra-thin films of polysulfone are prepared by spin coating down to thicknesses below 10 nm on an aluminum support and investigated by broadband dielectric spectroscopy. As a main result is was found that the glass transition temperature Tg does not depend on the film thickness for thicknesses larger than 10 nm. Secondly from the analysis of the dielectric strength it is concluded that the polysulfone segments form an adsorbed layer with a reduced mobility at the Al support having a thickness of ca. 5 nm.
The breakage of a fiber and its effect on the strain energy is studied in a model composite, this is, a single fiber embedded in a dogbone specimen. The fracture process is recorded by an acoustic emission device, the crack patterns are monitored under a microscope. A finite element analysis is performed in order to estimate the energy released by different failure scenarios. The abilities and limitations of the acoustic emission analysis in characterizing different failure types in fiber reinforced composites are evaluated.
The binding affinities of the six main hexabromocyclododecane (HBCD) stereoisomers and all of their possible 48 allylic pentabromocyclododecene (PBCD) metabolites to the endocrinous human transthyretin receptor (hTTR) were investigated and compared to the natural binder thyroxine, and the two brominated diphenyl ethers BDE-47 and 3-hydroxy-BDE-47. The endocrine disrupting potency was approximated by a combination of two methods: a surface matching with the natural binder thyroxine (T4) followed by approximation of free binding energies for various binding modes within hTTR. The results indicate slightly higher binding affinities for both BDE structures than for T4 itself and similarly high affinities for two trans-configurated PBCD isomers. For many other PBCD isomers, intermediate values were computed, whereas all HBCD diastereomers yielded significantly lower binding affinities.
1,2,5,6,9,10-hexabromocyclododecane (HBCD), a widely used flame retardant, is an ubiquitous contaminant in
the environment. Still, only little is known about the distribution and behavior in the environment such as
bioaccumulation or biotransformation of HBCD stereoisomers. In order to investigate enrichment and possible
bioisomerization of HBCD stereoisomers, Mirror Carps were exposed to pure (+)- and (-)-γ-HBCD, randomly
sampled after a predefined specific period and subjected to enantiomer-specific determination of α-, β-, and γ-
HBCD. No evidence for the isomerization of HBCD stereoisomers was observed in Mirror Carp fillets.
Ultrasonic phased array NDE has been applied to ensure the integrity of canisters for encapsulation of spent nuclear fuel. The performance of the NDE system is evaluated by the POD analysis. The POD analysis using a common method, â versus a, has been modified for the phased array ultrasonic inspections by two approaches: to take more influencing parameters into a, and to use a more sophisticated quantity as â. The POD with new a allows more detailed interpretation of POD for each parameter, and the new â gives more realistic POD. The methods are discussed and demonstrated with experimental data. In addition, an investigation of human factors is being planned and the plan is discussed.
Quantitative NDE methods play a key role when it comes to inspect components,
which requires high operational safety. UT-SAFT is one of the well-known reconstruction tools,
which provides information about the defect size. In this work we studied the use of phased array
technique in combination with the SAFT algorithm to inspect power plant components. As a first
example we inspected a real-sized mock-up model representing a part of a reactor pressure vessel with
a 180 mm-thick ferritic base material followed by a 6 mm-thick austenitic cladding layer. The phased
array probe was coupled at the outer ferritic surface. We detected and sized fatigue cracks within the
cladding with a depth ranging from 4 mm to 10 mm. Secondly, we investigated a mock-up model
resembling a nozzle including a thermo sleeve inlet and a maximum wall thickness of about 37 mm.
Artificially inserted notches with a depth of 3 mm could be detected and sized, where the thermo
sleeve is welded at the inside of the nozzle.
The visualization of sound propagation in solids is vital for transducer adaptation and
better understanding of complex test samples and their wave propagation modeling. In this work we
present an electrodynamic technique detecting the grazing sound beam with a 10 mm-sized electrodynamic
probe. The particle displacement along the samples surface was then measured as a function
of time and position. Adapting the electrodynamic probe and its coil alignment allows for measuring
the displacement components in all three dimensions. Thus horizontal and vertical particle
displacement with respect to the surface can be detected. A SNR of up to 40 dB could be achieved
within ferromagnetic and high conductive chrome steel when using a shear wave generated by an
angle beam probe. When dealing with nonconductive materials such as PMMA we obtained a reduced
SNR of 12 dB. We report on measurements of the sound field in complex weld joints. One example
shows a narrow gap weld joining a nickel alloy with a chrome steel. The weld of the 80 mm-thick test
block shows a distinct anisotropic texture. The system enables us to visualize the wave propagation
within the weld and indicates the reflection and scattering scenario and the energy losses due to both
the anisotropic structure and material defects.
Increasing demands in materials quality and cost effectiveness have led to advanced
standards in manufacturing technology. Especially when dealing with high quality standards in
conjunction with high throughput quantitative NDE techniques are vital to provide reliable and fast
quality control systems. In this work we illuminate a modern electromagnetic NDE approach using a
small GMR sensor array for testing superconducting wires. Four GMR sensors are positioned around
the wire. Each GMR sensor provides a field sensitivity of 200 pT/√Hz and a spatial resolution of
about 100 µm. This enables us to detect under surface defects of 100 µm in size in a depth of 200 µm
with a signal-to-noise ratio of better than 400. Surface defects could be detected with a SNR of up to
10,000. Besides this remarkably SNR the small extent of GMR sensors results in a spatial resolution
which offers new visualisation techniques for defect localisation, defect characterization and
tomography-like mapping techniques. We also report on inverse algorithms based on either a Finite
Element Method or an analytical approach. These allow for accurate defect localization on the µm
scale and an estimation of the defect size.
Impulse thermography is an active method for quantitative investigations of the near
surface region of various structures. It has recently been applied and optimized to applications in civil
engineering. For quantitative analysis of data recorded on the building site, the problems are manifold.
Here, the influence of the different surface properties on the detection and characterization of voids
and honeycombing simulated by polystyrene cubes and cubes prepared of porous concrete are
demonstrated.
Lamb waves travel in plates and hollow cylinders over large distances and propagate with multiple mode shapes. Therefore the waves can be used for integrity tests of large scale structures. Each propagating wave mode has a unique dispersive character and a frequency dependent vibration pattern. Therefore, by interacting with flaws each mode is assumed to generate an individual reflection pattern depending on the flaw type, flaw orientation and size. To extract this information a frequency as well as wave number dependent mode excitation is required ensuring a single mode excitation. The challenge, however, is to control the selective mode excitation electronically to allow a sequence of consecutive tests with different wave modes to collect the data. A method is proposed using phased array wedge transducers with fluid coupling for normal force excitation of Lamb wave modes. The excitation principle is investigated analytically on plates by modelling the wave generation in the wedge and the coupling between wedge and structure. The analytical results of the excitation principle are validated by corresponding experiments where the field patterns on the wedge surface and on the plate were scanned using a laser vibrometer. The directivity of the radiated field is investigated together with the direction dependent analysis of the mode content.
The determination of magnetic distortion fields caused by inclusions hidden in a
conductive matrix using homogeneous current flow needs to be addressed in multiple tasks of
electromagnetic non-destructive testing and materials science. This includes a series of testing
problems such as the detection of tantalum inclusions hidden in niobium plates, metal inclusion in
a nonmetallic base material or porosity in aluminum laser welds. Unfortunately, straightforward
tools for an estimation of the defect response fields above the sample using pertinent detection
concepts are still missing. In this study the Finite Element Method (FEM) was used for modeling
spherically shaped defects and an analytical expression developed for the strength of the response
field including the conductivity of the defect and matrix, the sensor-to-inclusion separation and the
defect size. Finally, the results also can be useful for Eddy Current Testing problems, by taking the
skin effect into consideration.
The spatial resolution in ultrasonic testing as a wave phenomenon in nature is limited to a
certain fraction of the wavelength, usually defined to be close to the Rayleigh criterion. In case of
complicated reflector surfaces – such as stress corrosion cracking - this limitation prevents an exact
visualization of the defect shape. There exist a few approaches to improve the spatial resolution, whose
reconstruction quality all in common also depend on the achieved signal-to-noise ratio of the raw data. In this
work we present a specific SAFT analysis, in which a high number of different angles of incidence produce a
sufficiently high number of different reflections at the crack edges resulting in an improved SNR. In doing
so, we reconstruct a coherent crack structure. First investigations were made at artificially simulated crack
configurations with different contours and curvatures in flat and cylindrical test blocks. The measurements
results visualized by representative scans – show details of crack design and crack orientation. We also will
present a comparison of the SAFT analysis between modelling and phased array measurements.
Within a know-how transfer project funded by the government conventional ultrasonic
technique was replaced by phased array technique for automated round-bar testing. Instead of
applying a great number of conventional probes to achieve acceptable volume coverage we used
curved linear arrays. The benefits of phased array technique such as programmable skew angles,
beamforming and beam positions, led not only to a significant decrease in inspection time, but also the
number of probes could be substantially reduced . Finally, the testing parameters for a large range of
bar-diameters could be adapted by software control instead of time-consuming mechanical
replacement. The probe-design was carried out by a proprietary modelling program. Both the
theoretical calculations as well as the latter experimental verifications revealed significant advantages
of curved arrays versus the planar types. A radial oriented probe offers perfect adaption to the
cylindrical shape of the specimen allowing wide variations of the sound field. Thus beam direction,
beam size and beam position could be optimized with respect to a minimum of inspection cycles, as
inspections have to be executed in-line during the production. A number of laboratory tests were
carried out on special test components. In order to achieve an optimal performance of the reference
rod we implemented three different types of reference reflectors: (i) flat-bottom-holes with diameters
of 0.8 mm and 1.2 mm, (ii) side-drilled-holes with a diameter of 0.7 mm for the detection of
volumetric flaws, and (iii) notches with a depth of 0.2 mm and 0.5 mm for the detection of surfaceoriented
defects. All laboratory tests were carried out with the COMPAS-XXL inspection system, a
proprietary development of BAM.
Control and data acquisition of automated multi-sensor systems - two examples from civil engineering
(2010)
This article illustrates a concept of predicting the time dependent deformation and creep rupture strength of carbon fibre reinforced plastics (CFRP). In the presented concept the viscoelastic behaviour of the resin is determined by creep rupture tests at different temperature and load levels. Out of the experiments the relaxation spectrum of the resin is modelled including the spread. With the help of the classical rule of mixture and a modified classical laminate theory the minimum strain rate for the composite will be determined. The results will be compared to experimental data. Furthermore the Monkman-Grant approach is used to determine the time-to-failure strain-rate relation. Therefore an elastic solution of the classical laminate theory is used including Puck´s failure criteria to compute the Monkman-Grant relation. A Monte Carlo Simulation will be done to include the spread of the Monkman-Grant relation. The results will be compared to experimental results of unidirectional specimens. Finally it will be explained how the lifetime of a pressure vessel can be computed using the explained concept.
Surface wave velocities over the sonic frequency range (<20 KHz) were measured on concrete specimens undergoing various cycles of loading and unloading. Acoustic Emission test (AE) was conducted simultaneously to monitor the microcracking activities. The sonic surface wave velocity was found to be highly stress-dependent. The observed changes in surface wavespeed are repeatable and follow a particular trend. By measuring the wave velocities in both loading and unloading phases, the effects of stress and stress-induced damages could be distinguished. The observed trend could be explained by a combination of acoustoelasticity and microcracking theories.
This contribution investigates laser-induced damage of thin film and bulk polymer
samples, with the focus on physical processes occurring close to the damage threshold. In-situ
real-time reflectivity (RTR) measurements with picosecond (ps) and nanosecond (ns) temporal
resolution were performed on thin polymer films on a timescale up to a few microseconds (µs).
A model for polymer thin film damage is presented, indicating that irreversible chemical
modification processes take place already below the fluence threshold for macroscopic damage.
On dye-doped bulk polymer filters (as used for laser goggles), transmission studies using fs-and
ps-laser pulses reveal the optical saturation behavior of the material and its relation to the
threshold of permanent damage. Implications of the sub-threshold processes for laser safety
applications will be discussed for thin film and bulk polymer damage.
The CCS technique involves the compression of emission gasses in deep geological layers. To guarantee the safety of the site, CO2-corrosion of the injection pipe steels has to be given special attention when engineering CCS-sites. To get to know the corrosion behaviour samples of the heat treated steel 1.72252CrMo4, used for casing, and the stainless injection-pipe steel 1.4034 X46Cr13 were kept at T=60 °C and ambient pressure as well as p=100 bar for 700 h - 8000 h in a CC 2-saturated synthetic aquifer environment similar to possible geological on-shore CCS-sites in the northern German Basin. The isothermal corrosion behaviour obtained by mass gain of the steels in the gas phase, the liquid phase and the intermediate phase gives surface corrosion rates around 0.1 to 0.8 mm/year at ambient pressure and much lower about 0.02 to 0.2 mm/year at 100 bar where the CO 2 is in its supercritical state. Severe pit corrosion with pit heights around 4.5 mm are only located on the 42CrMo4 steel. Main phase of the continuous complicated multi-layered carbonate/oxide structure is siderite FeCO 3 in both types of steel.
Dealing with first corrosion screening experiments to predict the reliability and safety of Germanys first Carbon Capture and Storage site in the northern Bassin of Germany, northwest of the Capital Berlin, laboratory experiments have been established to simulate the particular conditions at T=60 °C, highly saline aquifer water similar to 'Stuttgart Aquifer', but only at ambient pressure. With mounting 2 independent full 2-grade titanium autoclave systems (running up to 250 bar and 300 °C) pressures up to p=100 bar are possible. In 2010 a specific corrosion chamber of 2-grade titanium working up to 100 °C, flowing aqui fer water with different gas mixtures was designed to fit to a high cycle fatigue testing machine. Long term fatigue experiments simulating fatigue crack growth under corrosive environments will soon start. These experiments may not only help engineering a CCS site, but results can be used to improve the maintenance of geothermal energy production sites, especially moved parts such as pumps and shafts.
Claddings of different nickel based alloys were generated on a mild Steel (S235JR) and a stainless steel type 304 by Cold Metal Transfer (CMT). This welding procedure possesses a low degree of mixing between the Substrate and cladding material. Thus it improves the corrosion behaviour of the claddings. The aim of our investigations was to examine the effect of the welding parameters: energy per unit length, shielding gas and finishing surface treatment on the pitting corrosion behaviour of the claddings.
However, under Standard test conditions nickel based alloys are often resistant to pitting corrosion. Moreover these test methods are inaccurate and require a large period of time resulting from the iterative progress to determine the critical pitting temperature (CPT). A potentiostatic test method was modified using a high concentrated CaCI2-solution and a conventional three electrode measuring cell. The pitting corrosion behaviour is calculated from current noise charges. During the test the course of corrosion is detected online by the evaluation of electrochemical noise Signals while a continuous increase of temperature by a defined heating rate is realised.
Thus a critical pitting temperature can be estimated by only one attempt. Furthermore the deviation of the measured CPT is very low compared to Standard tests using gravimetrical and microscopic evaluation. That enables to figure out the influence of the welding parameters in an exact way.
The material parameters melt flow rate MFR, density D, notched impact strength N.I.S. at -30 °C, stress crack resistance FNCT and resistance to oxidative degradation Ox (determined by the increase of MFR) have been selected for a comparison of polyethylene grades for one design type in the “European Standard EN 15507 - Transport packaging for dangerous goods - Comparative material testing of polyethylene grades”. The parameters have a systematic relationship with design type tests. The notched impact strength at -30 °C and the resistance to oxidative degradation of polyethylene grades determined with test specimens of compression moulded sheets are directly comparable with drop tests at -18 °C of design types produced of these grades after pre-storage with 55 % nitric acid for 21 days at 40 °C. The impact of the pre-storage time of jerricans with 55 % nitric acid at 40 °C and 23 °C on the marginal drop heights in drop tests at -18 °C, on the MFR and on the tensile properties tensile strength, breaking elongation and the elastic modulus were investigated. Packaging design types (jerricans) made of three polyethylene grades from different producers were pre-stored with 55 % nitric acid for 21,42 and 84 days at 40 °C as well as for six months at 23 °C. The MFR and tensile properties of test specimens taken from the design type side walls as well as the marginal drop heights of the jerricans in drop tests at -18 °C were determined.
The values of the notched impact strength at -30 °C of polyethylene grades are not comparable with the marginal drop heights determined in drop tests at -18 °C. The oxidative damaging impact of nitric acid has a greater effect on the grade with lower resistance to oxidative degradation by reducing more significantly the marginal drop heights with increasing pre-storage time.
Pre-damage with 55 % nitric acid for 21 days at 40 °C, as recommended in ISO 16101 and EN 15507 caused an increase in the marginal drop heights of most design types in drop tests when compared with design types without pre-damage. The test results demonstrated clearly that pre-storage of the jerricans for six months at 23 °C caused a higher increase in the MFR and lower marginal drop heights of the jerricans in drop tests at -18 °C compared with pre-storage of the jerricans for 21 days at40 °C.
The mechanical properties change as a result of diffusion of nitric acid into the polyethylene grades and the reaction of the nitric acid with the polymers. The percentage decrease and increase in the tensile strength, breaking elongation and elasticity modulus of test specimens taken from the design type side walls after different pre-storage times were only partly comparable with the marginal drop heights in drop tests at -18 °C.
Strain measurement in structures witli the purpose of long-term structurai health inonitoring must provide reliable inforination about the structure’s behavior over the whole period of use. The user must be sure that installed sensors are validated and work to the utmost satisfactiou. For this purpose, sensor Systems are tested using special facilities. Bccause it is not easy to characterize the strain transfer quality from the host structure into surface-applied strain sensors, a unique testing facility has been developed. Originally developed for fiber Bragg grating based sensors, the KALFOS facility (= calibration of fiber optic sensors) can also be used for electrical strain sensors.
Calibration ineasurements are referenced by unbinsed Digital Image Correlation (D1C) and Electronic Speckle Pattern Interferometer (ESPI) methods. The strain transfer behavior can experimentally be analyzed and investigated under combined thermal and mechanical loading conditions and allows revealing wealuiesses in couimonly used attachment methodologies. The deformation of all members (particularly the coating/substrate - adhesive combination) in the sensing area is physically independently gained and recorded. Results achievcd allow precise description of the strain transfer function, Validation of the longterm strain sensor characteristics, matching of specific measurement requirements with environmental conditions, and, moreover, the verification of Standards for use of strain sensors.
How do application-related issues influence the reliability of fiber optic strain measurements?
(2011)
Fibre optic strain sensors are increasingly used and sensor systems are provided with specifications. Even if the performance is well specified, the strain characteristics of the sensor, strain transfer factor, mechanical stability under thermal influences, the performance of applied strain sensors can seriously differ from virgin sensor's the performance. The contribution will focus on issues that can deteriorate the sensor function or reduce the reliability of measurement results. Aspects are considered how to come to reliable strain measurements and how to validate strain measurements of applied sensors. Related to this topic, European activities like the recently started European COST TD1001 action, called (OfSeSa) will be presented.
Cathodic protection (CP) is a common method for rehabilitation of reinforced concrete structures suffering from Chloride induced corrosion. A sufficient protection of the corroding rebar can be ensured by use of several protection criteria. The use of these assessment criteria, in particular the so called 100 mV-criterion, can lead to erroneous resuits for certain unconventional arrangements of rebar and cp anode.
Therefore a joint research project of the Institute for Building Materials Research, RWTH-Aachen University, Germany, (ibac) and the Federal Institute for Materials Research and Testing, Berlin, Germany, (BAM) has been set up to determine the applicability of CP under arbitrary geometrical conditions. A special focus was set on the applicability of surface applied anode Systems for protection of the reinforcement of structures opposite to the accessible side (e.g. outer side of tunnel Shell, Bridge deck protected from inside a box girder) In this paper, the impact of the time dependent changes of the Polarisation behaviour of the rebar on the current and potential distribution is shown by means of parametric studies using the FEM method.
We studied Brillouin gain spectrum characteristics in dispersion-shifted fibers having compound GeO2-doping compositions in the fiber core to realize simultaneous measurement of distributed strain and temperature. Due to various dopant concentration alongside the radius of tested nonzero dispersion-shifted fibers several multiple Brillouin scattering resonances were observed in the stimulated Brillouin spectra arose through backscattering on higher acoustic modes which propagated along the fiber axis. As a result of the varying acoustic velocities, the Brillouin resonance peaks featured different temperature coefficients which can be used to accomplish the simultaneous measurement of fiber strain and temperature. We presented our first measurement results for NZDS Fujikura and LEAF Corning fiber and discussed the superior sensory suitability of the former fiber types.
The presently active standards on Computed Radiography (CR) need a major revision. It was observed by many users that the image quality for class B of EN 14784-2 is not achievable under the same exposure conditions as used for film exposure. A mathematical model was developed and tested, which allows the calculation of the image quality, proven by image quality indicators (IQI), depending on the fixed pattern noise and the efficiency of the used imaging plate (IP) scanner system. All tested IP scanner systems provide a fixed correlation between the measured signal/noise ratio (SNR) and the grey values in the digital images. The maximum achievable SNRmax depends on the fixed pattern noise of the plate (high dose limit). Depending on the exposure dose an optimum visibility of IQIs can be predicted by calculation and measured considering the attenuation coefficient for calculation of the contrast/noise ratio (CNR). The diameter of the just visible wire is proportional to 1/sqrt(CNR). The optimum tube voltage for best visibility of IQIs and maximum CNR depend on the exposure dose. The optimum tube voltage for best visibility is achieved only at exposures with high dose. A dose dependant optimal tube voltage was not observed for film radiography.
Instrumented measurements on radioactive waste disposal containers during experimental drop testing
(2011)
In context with disposal container safety assessment of containers for radioactive waste the German Federal Institute for Materials Research and Testing (BAM) performed numerous drop tests in the last years. The tests were accompanied by extensive and various measurement techniques especially by instrumented measurements with strain gages and accelerometers. The instrumentation of a specimen is an important tool to evaluate its mechanical behavior during impact. Test results as deceleration-time and strain-time functions constitute a main basis for the validation of assumptions in the safety analysis and for the evaluation of calculations based on finite-element methods. Strain gauges are useful to determine the time dependent magnitude of any deformation and the associated stresses. Accelerometers are widely used for the measuring of motion i.e. speed or the displacement of the rigid cask body, vibration and shock events. In addition high-speed video technique can be used to visualize and analyze the kinematical impact scenario by motion analysis. The paper describes some selected aspects on instrumented measurements and motion analysis in context with low level radioactive waste (LLW) container drop testing
Determining scatter ratios at high energies (> ~ 1MeV) presents challenges not immediately obvious from measurements at conventional X-ray energies. This includes reduced attenuation even in heavy elements as well as a stronger forward bias of scattering. In order to check the reliability of different measurement setups with regard to material thicknesses, distances, and collimation, attenuation and scattering were separately simulated using a Monte Carlo model. The simulation results help in understanding the sources of radiation scattered into the detection area, thereby aiding in eliminating undesired contributions.
Schadensfälle in den letzten zehn Jahren mit teilweise katastrophalen Folgen belegen, dass der Vermeidung von Rissen beim Schweißen von Rohrleitungen besondere Aufmerksamkeit zu schenken ist. In der Analyse solcher Schäden ist zu unterscheiden, ob die Risse bereits während oder kurz nach der schweißtechnischen Fertigung der Rohrkomponenten oder während des anschließenden Betriebes entstanden sind. Im vorliegenden Beitrag wird sich vor allem auf die Vermeidung einer Heiß- und Kaltrissbildung beim Schweißen von Rohrleitungen konzentriert und es werden weitere Forschungsperspektiven abgeleitet.
The extremely low acoustic impedance of polypropylene ferroelectret combined with its piezoelectric properties makes this material suitable for construction of aircoupled ultrasonic transducers for non-destructive testing. For the fabrication of transducers with a stable quality, the reproducibility of their key parameters is of interest.
The reproducibility was evaluated by means of (i) impedance spectroscopy and (ii) pulse-echo measurements. (i) Impedance spectroscopy was applied to identify the resonance frequency, the coupling factor and the acoustic impedance of several nominally identical transducers. (ii) Pulse-echo measurements yielded the signal form of these transducers.
The variation of the signal amplitude measured with pulseecho technique was about 10 dB. A part of this variation Comes from the deposition of transducer electrodes and another part from local variations of ferroelectret properties. The variation of the signal amplitude was caused by the observed variation of the coupling factor, which was also about 10 dB. The variation of the acoustic impedance was only about 1 dB, thus having no effect on the variation of the signal amplitude.
These results indicate that the variability can be reduced by improving the control of electrode deposition and by optimizing the production technology affecting the reproducibility of material properties.
Different types of lasers are used nowadays for a number of technological Solutions, Modem high power solid-state lasers with high brightness of Radiation like Fiber or disc lasers find ever more applications in welding technology. Apart from the replacement of the CC>2-iasers traditionaHy used fcr these purposes, they provide new technological possibilities of metal treatment, such as using industrial robots and remote welding with high power laser radiation. The possibility of flexible optical fiber delivery of the radiation to any point gives a great technological advantage and permits welding processes to be realized with complicated weld seam geomelries and different positions using a minimum of additional fixtures. The short wavelength of the high power solid state lasers (1.07 ’m) causes another advantage. The coefflcient of inverse 170
Bremsstrahlung absorption from free electrons in plasma for such radiation is about 100 times lower than for the COi-iaser radiation. Owing to this fact, using the solid state lasers allows it to avoid a negative influence of the welding plume.
However, a short wavelength can lead to another kind of laser Radiation attenuation, which is connected with the formation of a cloud consisting of small metal particles that absorb and scatter laser radiation. This cloud arises due to the condensation of hot metal vapor by flying out from the deep Penetration channel and broadening in relatively cold atmosphere over the metal Surface.
Some theoretical and experimental approaches were made in advance in Order to estimate the influence of the Condensed particles on laser radiation and welding quality.
In this paper a systematic study including the determination of the Cloud size and its dynamical characteristics is presented. The results were obtained within the scope of the first stage of the metal vapor condensation process Investigation during welding with high power fiber lasers.
A time domain spectrometer in the range of 0.5–2 THz was used for time of flight (ToF) measurements of THz pulses for imperfection detection in non metallic materials. The measurements were performed in comparison to the established ultra sound pulse echo (PE) and time of flight diffraction (ToFD) technique. No coupling agent and no contact to the surface is required for THz ToFD measurements. Plastic test specimen with notches, voids and drilled side holes were used to study reflected and diffracted response signals. No major differences were observed between the UT and THz ToFD records for the first surface of the notches, voids and holes. Additionally to the UT records also signals were obtained from its back side and a second raw of holes. The THz measurement is fast and has the potential to substitute UT applications in some industrial areas. Within the German project 'Handheld' the potential for miniaturization of the time domain equipment is explored for efficient application.
With CO2 being one reason for climate change carbon capture and storage (CCS) is discussed to mitigate climate change. When emission gases are compressed into deep geological layers CO2-corrosion can easily cause failure of injection pipes. Different steels 42CrMo4, X46Cr13 and X20Cr13 were tested as well as X35CrMo17 and X5CrNiCuNb16-4 in a laboratory Environment similar to the conditions of the CCS engineering site at the Northern German Bassin. Samples were exposed to synthetic aquifer water saturated with technical CO2 at a flow rate of 3 NL/h.
Corrosion rates obtained via mass loss vary in a wide range (0,005 to 2.5 mm/year). The precipitations within the corrosion scale revealed a complicated multiphase layer containing siderite FeCO3, goethite α-FeOOH, lepidocrocite γ-FeOOH, mackinawite FeS and akaganeite Fe8O8(OH)8Cl1,34 and spinelphases of various compositions.
Risikobasierte Überwachungsverfahren zur Lebensdauerverlängerung von bestehenden und neuen Bauwerken
(2011)
Diese Veröffentlichung enthält Konzepte zur Lebensdauerverlängerung von Bauwerken auf der Grundlage der Tragwerkszuverlässigkeitstheorie. Es werden aktuelle Forschungsergebnisse aus nationalen und europäischen Forschungsvorhaben vorgestellt. Den Schwerpunkt bildet die Verwendung von Bauwerksüberwachungsdaten unter Berücksichtigung von Messunsicherheiten zur Bestimmung der Tragwerkszuverlässigkeit. Dazu wird ein neuer Ansatz zur Bestimmung der A-posteriori Messunsicherheit vorgestellt. Es wird gezeigt, aufgrund welcher Eigenschaften der verwendeten probabilistischen Modelle die Zuverlässigkeit im Grenzzustand der Ermüdung in Bezug auf eine Lebensdauerverlängerung beeinflusst werden kann.
The debonding of a fiber in a glass fiber / epoxy composite under transverse loading is studied. The stress field in the interface as well as the energy release rate are analysed for two fiber volume fractions.
The circumferential propagation of an Interface crack starting at the center of a fiber which is located within a hexagonal fiber array is studied. The analysis is performed by a finite element Simulation under plane stress conditions. Two fiber volume fractions are considered, this is 30% and 70%. The stress distribution before and during crack propagation is calculated for different stages of the
crack. The crack opens by dominating tensile stresses in the first phase while it closes when propagating along the interface. The total energy release rate as well as the mode I and mode II parts are calculated. In the first phase the crack is driven by an increasing mode I energy release rate, indicating an unstable crack propagation. Then the mode II energy release rate increases rapidly and dominates the debonding process while the mode I part decreases and finally vanishes. Subsequently also the mode II part decreases, indicating stable crack propagation. In the last phase the crack becomes unstable again due to a strongly increasing mode I energy release rate. During the debonding process a remarkable change the mode ratio takes place.
The main features of the debonding process are similar for low and high fiber volume fraction. In case of the high fiber content, however, the mode I part is more pronounced and the maximum of the total energy release rate is shifted to lower crack angles.
Dry cask storage of spent fuel and high active waste front reprocessing is licensed and established in Germany for up to 40years so far. About 10years ago, the strategy has been shifted from centralized storage using facilities in Ahaus and Gorleben to cit-site storage facilities in Order to avoid immediate cask shipping from nuclear power plants. At present, several hundred casks are stored safeiy and without any major problem. BAM is highly involved in cask specific safety evaluations within the scope of licensing procedures as well as of quality assurance procedures during cask fabrication, loading and storage.
A major prerequisite for any cask storage license is a valid transport Type B license. Subsequently, cask transportability has to be ensured at any point during the entire storage period. So far, this requirement is met by continuous maintenance of the Type B license. Anyhow, IAEA Type B regulations do not consider permanently loaded storage casks that have the sole purpose of being finally shipped öfter decades of storage inducing ageing effects. No transport safety demonstration has to be performed on aged cask components.
Sensor based person tracking is a challenging
topic. The main objective is positioning in areas without
GPS connection, i.e. indoors. A research project is carried
out at BAM, Federal Institute for Materials Research and
Testing, to develop and to validate a multi-sensor system for
3D localization. It combines body motion sensing and a
guard system for the tracking and recording of the status of
persons. The so named BodyGuard system was designed for
sensor-based monitoring and radio-based transmission of
the movement of a person. Algorithms were developed to
transform the sensor data into a spatial coordinate. This
paper describes how the BodyGuard system operates, which
main components were used in the system, how the
individual sensor data are converted into 3D motion data,
with which algorithms the individual sensors are processed,
how individual errors are compensated and how the sensor
data are merged into a 3D Model. Final objective of the
BodyGuard system is to determine the exact location of a
person in a building, e.g. during fire-fighting operations.
A silicon MIS-structure prepared with thin layers of the super-ionic conductor LaF3 and Pd is used to detect hydrogen. The sensor is able to detect hydrogen in a concentration range from below one ppm to the lower flammable limit in air which is 4 vol.-%. The chip operates at room temperature which results in an extremely low energy consumption compared to other hydrogen sensors. Only once per day a short heating pulse is necessary to reactivate the sensor chip. In cooperation with the BAM, a long-term experiment was carried out. The duration of the measurement was about three months, with a hydrogen exposure every two weeks. The sensor signal remained stable over the measured period.
This paper presents the numerical modeling of the Lamb wave propagation in thin plates with the elastodynamic finite integration technique (EFIT) and its validation with the measured results. In general, Lamb waves offer an attractive method to detect the defects inside long plate like structures efficiently. However, such a nondestructive testing (NDT) requires profound understanding of the Lamb wave propagation in the plates, generation of the symmetric and anti-symmetric modes of different orders and their interaction with the defects of the materials. Modern simulation tools based on numerical methods such as the finite integration technique (FIT), the finite element method (FEM) and the boundary element method (BEM) can be used to model this NDT situation. The elastodynamic finite integration technique (EFIT) is an effective tool to model Lamb wave propagation in plates over long distances in an efficient way. With the help of the simulation results obtained from the EFIT tool the propagation of different symmetric and anti-symmetric modes is analyzed and thus a proper technique is developed to excite different modes and to separate them from each other precisely. A validation of the numerical results with the analytical results is also presented.
In this paper the Scaled Boundary Finite Element Method (SBFEM) is applied for the simulation of Lamb waves in cracked plates. This method is highly advantageous to study the interaction of different Lamb wave modes with cracks as the crack is not discretized and no refinement is required around the crack tip. Numerical examples are presented for the reflection of the fundamental symmetric and antisymmetric modes from cracks of different depth. The spatial Fourier transformation is employed to calculate the amplitudes of reflected Lamb wave modes. The results reveal possibilities to obtain details of the crack geometry in non-destructive testing and structural health monitoring applications.
Ultrasonic investigation of inhomogeneous anisotropic materials such as austenitic welds is complicated because its columnar grain structure leads to curved energy paths, beam splitting and asymmetrical beam profiles. A ray tracing model has potential advantage in analyzing the ultrasonic sound field propagation and there with optimizing the inspection parameters. In this contribution we present a 2D ray tracing model to predict energy ray paths, ray amplitudes and travel times for the three wave modes quasi longitudinal, quasi shear vertical, and shear horizontal waves in austenitic weld materials. Inhomogenity in the austenitic weld material is represented by discretizing the inhomogeneous region into several homogeneous layers. At each interface between the layers the reflection and transmission problem is computed and yields energy direction, amplitude and energy coefficients. The ray amplitudes are computed accurately by taking into account directivity, divergence and density of rays, phase relations as well as transmission coefficients. Ultrasonic sound fields obtained from the ray tracing model are compared quantitatively with the 2D Elastodynamic Finite Integration Technique (EFIT). The excellent agreement between both models confirms the validity of the presented ray tracing results. Experiments are conducted on austenitic weld samples with longitudinal beam transducer as transmitting probe and amplitudes at the rear surface are scanned by means of electrodynamical probes. Finally, the ray tracing model results are also validated through the experiments.
Ultrasound propagation in inhomogeneous anisotropic materials is difficult to examine because of the directional dependency of elastic properties. Simulation tools play an important role in developing advanced reliable ultrasonic testing techniques for the inspection of anisotropic materials particularly austenitic cladded materials and dissimilar welds. A 2-D Ray tracing method is developed for evaluating ray path, amplitude and travel time for three wave modes namely quasi longitudinal wave (qP), quasi shear vertical wave (qSV) and shear horizontal waves (SH) in anisotropic materials such as austenitic cladded materials. The inhomogenity in the anisotropic material is represented by discretizing the anisotropic region into several homogeneous layers. The ray paths are traced during its propagation through the various interfaces between those layers. At each interface the problem of reflection and refraction is solved. The ray amplitudes are computed by taking into account the directivity and phase relations. Ray divergence variation and ray transmission coefficients at each refraction boundary are considered. The Ray tracing results for ultrasonic field profiles in austenitic cladded materials are validated quantitatively by 2-D Elastodynamic Finite Integration Technique (EFIT) results and by the experiments.
Some nonlinear optical properties such as the nonlinear refractive index and the nonlinear effective absorption, as well as the laser-induced single-pulse ablation threshold are characterized for a series of binary and ternary silicate glasses upon irradiation with near-infrared femtosecond laser pulses (800 nm, 130 fs). The laser-induced ablation threshold varies from 2.3 J/cm² in case of potassium silicate glass up to 4.3 J/cm² in case of Fused Silica. Nonlinear refractive indices are qualitatively similar within the range 1.7-2.7×10-16 cm²/W. Complementary optical and physico-chemical properties like band gap energy and the glass transformation temperature have been measured for all the glasses.
Broadband dielectric spectroscopy (BDS), capacitive scanning dilatometry (CSD) and differential ac-chip calorimetry (DACC) were used to examine the glass transition and segmental dynamics of ultrathin poly(bisphenol A carbonate) (PBAC) films. An increase of Vogel temperature (T0) as well as glass transition temperature (Tg) with decreasing film thickness was observed when the thickness is less than 20 nm. Moreover, the segmental relaxation time at a fixed temperature was found to increase for the aluminium (Al) capped PBAC films (<20 nm) in the BDS measurements, whereas in the DACC measurements no thickness dependency of the segmental dynamics was detected within the experimental error limit for the supported PBAC films (10-55 nm). These properties are discussed in terms of the thin film geometry and the relevant interfacial interaction between the polymer and the substrate.
Transport packages for spent fuel have to meet the International Atomic Energy Agency requirements for different transport conditions. Physical state of spent fuel and fuel rod cladding as well as geometric configuration of fuel assemblies are important inputs for the evaluation of package capabilities under these conditions. In this paper, the mechanical behaviour of high burn-up spent fuel assemblies under transport conditions is analysed with regard to assumptions to be used in the activity release and criticality safety analysis. In particular the different failure modes of the fuel rods (fine cracks or complete breakage), which can cause release of gas, volatiles, fuel particles or fragments have to be properly considered in these assumptions. In view of the complexity of interactions between the fuel rods as well as between fuel assemblies, basket, and cask containment, the exact mechanical analysis of such phenomena is nearly impossible. The gaps in information concerning the material properties of cladding and pellets, especially for the high burn-up fuel, make the analysis more complicated additionally. In this context some practical approaches based on experiences of BAM Federal Institute for Material Research and Testing within safety assessment of packages for transport of spent fuel are discussed.
The surface of a shape memory poly(ester urethane)
(PEU) was either black- or blue-colored to obtain switchable
quick response (QR) codes after laser engraving and thermomechanical
functionalization (programming). The investigation
of dye and functional stability against UVA and hydrolytic
aging (at 23 and 60 °C) gave that contrast decline due to dye
decolorization (in case of UVA aging) or distinct dye diffusion
(in case of hydrolytic aging) finally inhibited the QR code
readability. By contrast, PEU as marked base material could be
adequately fixed and recovered even when the Michelson
contrast in the QR code region was falling in course of aging
below a crucial value of 0.1, whereupon the QR code was no
longer readable. Hence, we concluded that under the given
experimental conditions the decisive parameter for tag
applicability was the surface contrast.
Here we present a suitable tag prototype with phasesegregated
poly(ester urethane) (PEU) as base material for
effectively switching a quick response (QR) code in its surface
from non-readable to readable. In comparison with recently
introduced tags (different geometry) we minimized the
thickness from plaque (2 mm) to foil size (0.5 mm) and reduced
the lateral QR code length from 15 to 5 mm. Subsequent to
surface-dyeing by means of guest diffusion, the QR code was
laser-engraved. The implementation of thermo-mechanical
functionalization via tensile deformation and cooling resulted in
the formation of stable shapes, which exceeded the barrier of
QR code readability at an elongation of 20%. Once
functionalized, tags were switched on demand by heating. As
such the recovery of the PEU was accomplished and the QR
code could again be read out. QR code carriers based on shape
memory polymer can be used in product and brand protection
applications.
In geothermal power plants the materials used in pumps are loaded cyclically and
exposed constantly to the highly corrosive hot thermal water. The lifetime reduction
of AISI 420C (X46Cr13, 1.4034) is demonstrated in in-situ-laboratory experiments
(T=60 °C, geothermal brine: Stuttgart Aquifer flow rate: 9 l/h, CO2). S-N plots,
micrographic-, phase-, fractographic- and surface analysis were applied to obtain
sustainable information on the corrosion fatigue behavior. Maximum number of
cycles (here 12.5 x 106 cycles to failure) is reached at σa =173 MPa. No typical
fatigue strength exists and passive corrosion fatigue may be identified as failure
cause.
Influence of selected aspects of the mixture proportioning on the performance of repair mortars
(2012)
Automated multi-sensor systems in civil engineering for condition assessment of concrete structures
(2012)
In this study a method for early damage detection is investigated based on the directed excitation and measuring of Lamb waves (guided waves). The objective is to make a statement about the practicability of a Lamb wave generator (LWG) and about the application relevant parameters (specimen materials and dimensions, wave characteristics, excitation, transmission und reflection). Guided waves enable an effective differentiation of structural and defective indications as well as a classification of different defect types. For the investigations, a LWG was developed which combines the advantages of the single excitation of a piezoelectric actuator and the possibility of a group excitation. Algorithms were developed to identify and analyze damage patterns (cracks, wholes, weakening).
Reducing risks and confining them to an acceptable level can be regarded as an essential commitment of technical applications for safety purposes and the public security measures.
Rating the efficiency of such measures requires an assessment of the risk that is supposed to be reduced. However, approaching this subject means to face a plethora of existing literature and an ongoing discussion if and how this can be achieved. On one hand, it remains a rather uncertain estimate particularly if it comes to rare interrupting events. On the other hand, making a decision responsibly requires a certain rational base. Several approaches exist for assessing risks, from verbal to quantitative, depending on the individual case. The frequently quoted Delphi technique represents the verbal one, others such as the Bayesian statistics a quantitative one or the consequence/probability matrix in-between.
A problem remains with understanding probability. Even if an event is highly unlikely it may happen right now.
A new planar sensor element for continuous coulometric trace humidity measurements in industrial gases has been developed. In order to ensure precise measurements a calibration facility including a precision dew point hygrometer as a reference device was developed. The sensor can measure the humidity in the frost point temperature range of -20 °C to -80 °C and has an expanded uncertainty of 2 K, a fast reaction time and a settling time of the entire system from 15 to 30 min.
The main goal of the presented work was to evolve a multifunctional beam composed out of fiber reinforced plastics (FRP) and an embedded optical fiber with various fiber Bragg grating sensors (FBG). These beams are developed for the use as structural member for bridges or industrial applications. It is now possible to realize large scale cross sections, the embedding is part of a fully automated process and jumpers can be omitted in order to not negatively influence the laminate. The development includes the smart placement and layout of the optical fibers in the cross section, reliable strain transfer, and finally the coupling of the embedded fibers after production. Micromechanical tests and analysis were carried out to evaluate the performance of the sensor. The work was funded by the German ministry of economics and technology (funding scheme ZIM). Next to the authors of this contribution, Melanie Book with Röchling Engineering Plastics KG (Haren/Germany) and Katharina Frey with SAERTEX GmbH & Co. KG (Saerbeck/Germany) were part of the research group.
Limited access to the object of relevance is often an essential problem in testing routines, e.g. for non-destructive testing of industry facilities or components of means of transportation. The presented project is about the development of a non-destructive testing method for application over great distances (up to 100 m). The method is based on directed excitation and measuring of Lamb waves (guided waves). It enables an effective differentiation of structural and defective indications as well as a classification of different defect types.
The advantage of guided waves is the ability of propagation over great distances. This offers innovative possibilities for the investigation of large or difficult to access constructions. The testing method can be helpful in a broad variety of applications. It is useable for the characterization of plane or cylindrical, thin-walled surfaces of metal or fiber laminated materials. Particularly the investigation of aircraft wings and other aerospace components as well as the investigation of pipelines are addressed fields of application.