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Eingeladener Vortrag
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Thermografische ZfP-Verfahren erlauben die Erkennung einer Vielzahl von Defekten in unterschiedlichsten Werkstoffen. Neue Ansätze unter Verwendung von Lasern ermöglichen darüber hinaus die Prüfung auf Oberflächenrisse. Wir stellen die neuesten Entwicklungen dieser vielversprechenden Technik vor und zeigen warum deren Einsatz potentiell die Standardprüfverfahren Magnetpulver- bzw. Eindringprüfung für eine Reihe von Prüfproblemen beerben könnte. Hierzu stellen wir die Prüfergebnisse zu unterschiedlichen metallischen Werkstoffen, Rissgrößen und -typen in Abhängigkeit der Prüfparameter vor. Die aktuelle Grenze der Nachweisempfindlichkeit für die mittels klassischer Thermografie schwer prüfbaren hochreflektierenden Metalloberflächen liegt mit Rissbreiten und -tiefen von weni-gen Mikrometern im Bereich der fluoreszierenden Magnetpulver- und Eindringprüfung. Dabei sind weder Verbrauchsmittel noch eine Oberflächenpräparation notwendig und eine Prüfung kann berührungslos und automatisiert über Entfernungen im Meter-Bereich erfolgen.
The metal magnetic memory (MMM) technique relies on the measurement of stress-induced self-magnetic leakage fields (SMLFs) at the stress concentration zones (SCZs) of ferromagnetic materials during mechanical loading. However, there is an associated change in geometry of the specimen along with the stress due to plastic deformation. This paper presents a three-dimensional finite element (3D-FE) analysis of the stress-induced geometry effect on SMLFs in notched specimens during tensile deformation. The tangential (Hx) and normal (Hy) components of the SMLF signals have been predicted from the deformed specimens caused by different levels of tensile stress. Key parameters from the SMLF signals are determined for the possible estimation of damage in the specimen under tension. Studies reveal that the stress-induced geometry effect has a great influence (about 20%) on the SMLF signals, especially in the plastic deformation stage. The results show that the peak amplitude could be used for the estimation of different deformation stages under tension. The study also reveals that the SMLF signal is influenced by the thickness of the tensile specimen. The model-predicted thickness profile has also been experimentally validated.
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.
When dealing in ultrasonic testing with inhomogeneous material structure
data interpretation can be rather difficult. This is especially the case when using
anisotropic dissimilar welds made from austenitic steel or nickel based alloys, which are
currently used for modern power plant concepts. For better understanding of the
complex interaction between the sound field and the component under test, the
visualization of sound propagation in solids is a substantial task to increase the
probability of detection of relevant defects. However, there exist only a small number of
appropriate techniques published today, such as scanning laser interferometer,
piezoelectric and optical approaches in case of transparent solids. In this work we
present an electrodynamic technique providing a simple use and a high signal to noise
ratio. By detecting the grazing beam with an electrodynamic probe with a size smaller
than 10 mm, we measured the particle displacement as a function of time with a spatial
resolution in the order of 1 mm. Adapting the electrodynamic probe and its coil
alignment allows for measuring the displacement components in all three dimensions.
This comprises the detection of the horizontal and vertical particle displacement with
respect to the surface and thus also the transformation from longitudinal waves into
transversal waves and vice versa is possible. A SNR of higher than 36 dB could be
achieved within ferromagnetic and high conductive chrome steel when using a
transversal wave generated by an angled beam transducer. We report on measurements
of the sound field in complex weld joints. One example shows a 10 mm thick narrowgap
weld joining a nickel alloy with a chrome steel yielding a substantial anisotropy of
the weld structure. The test system enables us to visualize the wave propagation within
the weld and indicates the reflection scenario and the energy losses due to both the
anisotropic structure and material defects.
When dealing in ultrasonic testing with
inhomogeneous material structure data interpretation can be
rather difficult. This is especially the case when using anisotropic
dissimilar welds made from austenitic steel or nickel based alloys,
which are currently used for modern power plant concepts. In
this work we present an electrodynamic technique to visualize
sound waves with frequencies up to 3 MHz in steel components
providing a simple use and a high signal-to-noise ratio. By
detecting the grazing beam with an electrodynamic probe, we
measured the particle displacement as a function of time with a
spatial resolution in the order of 1 mm. Adapting the
electrodynamic probe and its coil alignment allows for measuring
the displacement components in all three dimensions. This
comprises the detection of the horizontal and vertical particle
displacement with respect to the surface and thus also the
transformation from longitudinal waves into transversal waves
and vice versa. We report on measurements of the sound field in
a complex narrow-gap weld, joining a nickel alloy with a chrome
steel with a substantial anisotropy of the weld structure. The test
system enables us to visualize the wave propagation within the
weld and indicates the reflection scenario and the energy losses
due to both the anisotropic structure and material defects.
When dealing in ultrasonic testing with inhomogeneous and anisotropic material structure such as
diverse types of components made from austenitic or nickel based cast, which are currently used
for modern power plant concepts, data interpretation is quite difficult. For better understanding of
the complex interaction between the sound field and the component under test, the mathematical
modeling of sound propagation in solids is a substantial task to increase the probability of
detection of relevant defects.
First we present a mathematical approach for modeling the three dimensional transient
particle displacement as a function of time in each point in a half space excited by an impulsive
point load at the surface. The transient ultrasonic field of a rectangular array element is calculated
with this approach by a point source synthesis. Based on this solution we model the wave
propagation of a phased array transducer by time delayed superposition of the wave field of the
transducer elements.
Next we use an electrodynamic technique to visualize the grazing sound field at the surface
of a test block radiated by a phased array probe. By detecting the grazing beam at the samples
surface with a small electrodynamic probe, we measured the particle displacement as a function of
time. It allows for measuring the displacement in all three spatial directions. This comprises the
detection of the horizontal and vertical particle displacement with respect to the surface and thus
also the detection of longitudinal and shear waves is possible.
The calculated and measured wave fields will be compared for different delay laws in
isotropic and transversely isotropic media. The results support the theoretical activities to model
the wave propagation and to find optimal testing parameters for different components and
configurations.
Die Messung spontaner magnetischer Streufelder ferromagnetischer Materialien wird als neue, Metal Magnetic Memory (MMM) genannte, Methode der zerstörungsfreien Prüfung (ZfP) angesehen, Schädigungen frühzeitig vorherzusagen. Die MMM Methode versucht, die sich gleichzeitig mit der Schadensentwicklung ausbildende lokale magnetische Struktur für die ZfP zu nutzen und zwar schon vor der eigentlichen Rissinitiierung. Das zugehörige Regelwerk ISO 24497 verspricht neben der Detektion von Mikrorissen und Inhomogenitäten des Werkstoffgefüges auch die Bestimmung des (Eigen-) Spannungszustandes. Neue, an der Bundesanstalt für Materialforschung und -prüfung für die ZfP angepasste GMR (Giant Magneto Resistance)-Sensorik erlaubt Magnetfeldmessungen mit einer Ortsauflösung im Mikrometerbereich. Mit höherer Ortsauflösung zeigen sich Unterschiede, jedoch keine Widersprüche zu bisher publizierten Daten. Ihnen wesentlich ist, dass es einige verwertbare Hinweise auf einen Zusammenhang von Restfeldmagnetisierung und Materialeigenschaften gibt.
Measurement of spontaneous magnetic stray field signals has been reported to be a promising tool for capturing macro-scale information of deformation states, defects and stress concentration zones in a material structure. This paper offers a new method for self-magnetic leakage field detection using a magneto-optical (MO) hand-held microscope. Its sensor has a dynamic field range between ±0.05 and ±2 kA/m and a lateral optical resolution of approx. 10 µm. We examined flat tensile test specimens of metastable austenitic steel AISI 304. Static tensile tests were repeatedly interrupted at various predetermined states of strain and the magnetic information was measured by the MO system. Comparative measurements using a high-precision magnetic field GMR-sensor, verify the outstanding capability of the MO microscope regarding spatial resolution of magnetic fields.
Evaluation of high spatial resolution imaging of magnetic stray fields for early damage detection
(2017)
The paper discusses the evaluation of elastic and plastic strain states in two low-carbon steels of the same steel group with high spatial resolution GMR (giant magneto resistance) sensors. The residual stress distributions of tungsten inert gas welded plates were determined by means of neutron diffraction as a reference. The normal component of local residual magnetic stray fields arise in the vicinity of the positions of maximum stress. The experiments performed on flat tensile specimen indicate that the boundaries of plastic deformations are a source of stray fields. The spatial variations of magnetic stray fields for both the weld and the tensile samples are in the order of the earths magnetic field.