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Eingeladener Vortrag
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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.
Visualization of material defects - modern approaches in acoustical and electrical NDE-methods
(2008)
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. Fast NDE-systems using a high degree
of automatisation can be used for both determining the degree of integrity of the
components under test and indicating a change of production parameters as well.
However, independently of the applied NDE method and the underlying physical
principle a reliable visualisation of hidden defects within the component under test is
based on a sufficient high signal to noise ratio (SNR) and a high spatial resolution. In this
talk we illuminate two standard NDT methods such as Ultrasonic Testing and Eddy
Current Testing and show their physical principles also discussing the interaction
between sound waves or induced eddy currents with different kinds of material defects.
This introduction substantiates the attainable SNR and spatial resolution of both methods
with respect to defect sizing and defect classification. As a first future prospect we report
on the SAFT-algorithm to improve SNR and spatial resolution paving the way for a flaw
sizing approach in ultrasonic inspection. As a second modern NDE approach we
represent the use of small magnetoresistance sensor arrays for EC testing of Al-laser
welds or for testing superconducting wires. The high sensitivity and small extent of GMR
sensors results in a remarkably SNR and spatial resolution offering new visualisation
techniques for defect localisation, defect characterization and tomography-like mapping
techniques.
Viscoelastic properties of cellular polypropylene ferroelectrets (PP FEs) were studied at low
frequencies (0.3–33 Hz) by dynamic mechanical analysis and at high frequencies (250 kHz) by laser Doppler vibrometry. Relaxation behavior of the in-plane Young’s modulus (Y´
11~1500 MPa at room temperature) was observed and attributed to the viscoelastic response of polypropylene matrix.
The out-of-plane Young’s modulus is very small (Y´33≈0.1 MPa) at low frequencies, frequency- and stress-dependent, evidencing nonlinear viscoelastic response of PP FEs. The highfrequency mechanical response of PP FEs is shown to be linear viscoelastic with Y´33≈0.8 MPa. It is described by thickness vibration mode and modeled as a damped harmonic oscillator with one degree of freedom. Frequency dependence of Y*33 in the large dynamic strain regime is described by the broad Cole-Cole relaxation with a mean frequency in kHz range attributed to the Dynamics of the air flow between partially closed air-filled voids in PP FEs. Switching-off the relaxation contribution causes dynamic crossover from the nonlinear viscoelastic regime at low frequencies to the linear viscoelastic regime at high frequencies. In the small strain regime, contribution of the air flow seems to be insignificant and the power-law response, attributed to the mechanics of polypropylene cell walls and closed air voids, dominates in a broad frequency range. Mechanical Relaxation caused by the air flow mechanism takes place in the sound and ultrasound frequency range (10 Hz–1MHz) and, therefore, should be taken into account in ultrasonic applications of the PP FEs deal with strong exciting or receiving signals.
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.
Sicherheitsrelevante und zyklisch hoch belastete Bauteile erfordern zur Vermeidung von kostenintensiven Ausfällen besonders stabile Prozessparameter. Bereits sehr kleine Randzonenfehler können unter zyklischer Bauteilbelastung zu Risswachstum und letztendlich zum Bauteilversagen führen. Die frühzeitige Erkennung von Randzonenfehler in Hochleistungsbauteilen wie z.B. Zahnräder, Ritzelwellen und Kurbelwellen erfordert daher eine leistungsfähige zerstörungsfreie Oberflächenrissprüfung, die es ermöglicht in den hochbeanspruchten Funktionsflächen auch Härterisse, Schleifrisse oder Zundereinschlüsse zu detektieren.
Hierzu sind in den letzten Jahren einige neue, innovative Oberflächenprüfverfahren wie die laserangeregte Thermografie und die Streuflussprüfung mit hochauflösenden GMR-Sensoren oder magnetooptischen Verfahren entwickelt worden. Zusätzlich zur hohen Empfindlichkeit zeichnen sich diese innovativen Verfahren durch einen schnellen und teils auch berührungslosen Einsatz aus. Da die noch relativ neu-en Verfahren naturgemäß noch nicht normativ verankert sind, wurden auch bereits erste Validierungen durchgeführt. Um die Leistungsfähigkeit der Verfahren eingehend zu untersuchen, erfolgten Testreihen an verschiedenen Testkörpern in Bezug auf Ortsauflösung, Empfindlichkeit, Automatisierung und Bewertung der Messsig-nale.
Neben den neuen Verfahren und ihren ersten Schritten hin zur Validierung kamen als Referenz auch die „klassischen“ Verfahren der Magnetpulver- und Wirbelstromprüfung zum Einsatz, deren Leistungsfähigkeit durch angepasste Sondenentwicklung auch für sehr kleine Oberflächendefekte nochmals unter Beweis gestellt wurde. Zusätzlich wurde an einigen Testkörpern eine hochauflösende CT durchgeführt. Die Ergebnisse dieses Vergleiches werden vorgestellt und Möglichkeiten sowie Grenzen der einzelnen Verfahren herausgearbeitet.
Stress corrosion cracking is a transcrystalline or intercrystalline crack formation in materials which
occurs under the influence of static tensile stress or residual stress and a specific aggressive
medium such as chloride containing substances.
This special sort of crack formation is involved in complex crack configurations, which may
only insufficiently be captured by conventional ultrasonic probes with fixed angles of incidence.
Only a number of different beam angles produce sufficient reflection to reconstruct the complete
defect shape from measured ultrasonic data. The SAFT algorithm, which was recently successfully
used in many industrial NDT-applications, is a promising tool for the reconstruction process. In
addition, the combination of phased array technique and SAFT was developed in several projects
by BAM, Berlin. Investigations using phased array equipment were performed to look into crack
configurations in test blocks with different surface curvatures. UT-SAFT has been used for the
analysis of spark-eroded notches simulating stress corrosion cracks at the thermo sleeve weld of a
nozzle. For comparison, UT-SAFT has also been applied for the analysis of real reflectors at the
same position in a nozzle used in a power plant, which was repaired later on. SAFT-scans received
from reconstructed ultrasonic measurement data confirm the practical usefulness of the SAFTalgorithm
developed by BAM.