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Organisationseinheit der BAM
An approach to adhesive bond characterisation using guided acoustic waves in multi-layered plates
(2021)
An approach for the non-destructive characterisation of adhesive bonds using guided ultrasonic waves is presented. Pulsed laser radiation is used to thermoacoustically excite broadband ultrasonic waves in a multi-layered sample, consisting of a metal plate adhesively joined to a polymeric layer using synthetic resin. The resulting signals are received by a purpose-built piezoelectric transducer. Varying the distance between excitation and detection yields spatio-temporal measurement data, from which the dispersive properties of the propagating waves can be inferred using a two-dimensional Fourier transform, assuming the plates to act as coupled waveguides. Coupled multi-layered waveguides show an effect referred to as mode repulsion, where the distance between certain modes in the frequency-wavenumber domain is assumed to be a measure of coupling strength. Measurements at different stages of curing of the adhesive layer are performed and evaluated. A comparison of the results shows changes in the dispersive properties, namely an increased modal bandwidth for the fully cured sample as well as an increased modal distance.
Guided waves (GW) are of great interest for non-destructive testing (NDT) and structural health monitoring (SHM) of engineering structures such as for oil and gas pipelines, rails, aircraft components, adhesive bonds and possibly much more. Development of a technique based on GWs requires careful understanding obtained through modelling and analysis of wave propagation and mode-damage interaction due to the dispersion and multimodal character of GWs. The Scaled Boundary Finite Element Method (SBFEM) is a suitable numerical approach for this purpose allowing calculation of dispersion curves, mode shapes and GW propagation analysis. In this article, the SBFEM is used to analyse wave propagation in a plate consisting of an isotropic aluminium layer bonded as a hybrid to an anisotropic carbon fibre reinforced plastics layer. This hybrid Composite corresponds to one of those considered in a Type III composite pressure vessel used for storing gases, e.g., hydrogen in automotive and aerospace applications. The results show that most of the wave energy can be concentrated in a certain layer depending on the mode used, and by that damage present in this layer can be detected. The results obtained help to understand the wave propagation in multi-layered structures and are important for further development of NDT and SHM for Engineering structures consisting of multiple layers.
Structural health monitoring (SHM) is a term that groups together techniques adopted to evaluate in a continued fashion the structural integrity and degradation of technical appliances. SHM is particularly attractive for components that are difficult to access or expensive to take off-line. Among many other techniques, SHM can be performed using ultrasonic guided waves (UGW) which have an advantage of traveling over Long distances. Various guided wave modes exist along with many methods for their generation and sensing, e.g by means of interdigital transducers (IDT). This contribution is dedicated to the design and characterization of a flexible piezopolymerbased IDT which allows for the selective excitation of UGW, resulting in more straightforward data analysis. The designed IDT was characterized using a 3D Laser Doppler Vibrometer (3D LDV) in the air to identify and analyze the IDT’s Vibration modes. Then the transducer was mounted on an aluminum plate, and the generated wavefield was measured with the 3D LDV.
According to this investigation, we demonstrate that it is possible to selectively excite desired guided wave mode, namely the A0 mode, suppressing the excitation of the S0 mode. Moreover, the measured wavefield allows for analysis of the directivity of the designed IDT. All in all the results show good correlation between theoretical predictions and measured values, thus allowing to use the current design in terms of selective excitation as it is.
Composite-overwrapped pressure vessels (COPV) are increasingly used in the transportation industry due to their high strength to mass ratio. Throughout the years, various designs were developed and found their applications. Currently, there are five designs, which can be subdivided into two main categories - with a load-sharing metal liner and with a non-load-sharing plastic liner. The main damage mechanism defining the lifetime of the first type is fatigue of the metal liner, whereas for the second type it is fatigue of the composite overwrap. Nevertheless, one damage type which may drastically reduce the lifetime of COPV is impact-induced damage. Therefore, this barely visible damage needs to be assessed in a non-destructive way to decide whether the pressure vessel can be further used or has to be put out of service. One of the possible methods is based on ultrasonic waves. In this contribution, both conventional ultrasonic testing (UT) by high-frequency bulk waves and wavenumber mapping by low frequency guided waves are used to evaluate impact damage. Wavenumber mapping techniques are first benchmarked on a simulated aluminium panel then applied to experimental measurements acquired on a delaminated aluminium-CFRP composite plate which corresponds to a structure of COPV with a load-sharing metal liner. The analysis of experimental data obtained from measurements of guided waves propagating in an aluminium-CFRP composite plate with impact-induced damage is performed. All approaches show similar performance in terms of quantification of damage size and depths while being applied to numerical data. The approaches used on the experimental data deliver an accurate estimate of the in-plane size of the large delamination at the aluminium-CFRP interface but only a rough estimate of its depth. Moreover, none of the wavenumber mapping techniques used in the study can quantify every delamination between CFRP plies caused by the impact, which is the case for conventional UT. This may be solved by using higher frequencies (shorter wavelengths) or more advanced signal processing techniques. All in all, it can be concluded that imaging of complex impact damage in fibre-reinforced composites based on wavenumber mapping is not straightforward and stays a challenging task.
Composite pressure vessels are important components in the storage of gases under high pressure. Among others, a common type of pressure vessel is made of a metal liner overwrapped with a fibre-reinforced plastic material. Conventional hydrostatic tests, used to assess the integrity of pressure vessels, may overstress the material and thus reduce the remaining lifetime of the tested component. Therefore, a truly non-destructive structural health monitoring (SHM) system would not only ensure a safer usage and extended lifetime, but also remove the necessity for periodic inspection and the testing of pressure vessels. The authors propose the use of guided ultrasonic waves, which have the potential to detect the main damage types, such as cracking in the metal liner, fibre breaks and composite matrix delamination. For the design of such an SHM system, multimodal ultrasonic wave propagation and defect-mode interaction must be fully understood. In this paper, simulation results obtained by means of finite element modelling (FEM) are presented. Based on the findings, suggestions are made regarding appropriate wave modes and their interaction with different flaw types, as well as the necessary excitation and suitable sensor configurations. Finally, a first approach for a reliable SHM system for composite pressure vessels is suggested.
Temperature Compensation Strategies for Lamb Wave Inspection using Distributed Sensor Networks
(2022)
The application of temperature compensation strategies is crucial in structural health monitoring approaches based on guided waves. Actually, the varying temperature influences the performance of the inspection system inducing false alarms or missed detection, with a consequent reduction of reliability. This paper quantitatively describes a method to compensate the temperature effect, namely the optimal baseline selection (OBS), extending its application to the case of distributed sensor networks (DSN). The effect of temperature separation between baseline time-traces in OBS are investigated considering multiple couples of sensors employed in the DSN. A combined strategy that uses both OBS and frequent value warning is considered. Theoretical results are compared, using data from two several experiments, which use different frequency analysis with either predominantly A0 mode or S0 mode data or both. The focus is given on the fact that different paths are available in a sensor network and several possible combination of results are available. Nonetheless, introducing a frequent value warning it is possible to increase the efficiency of the OBS approach making use of fewer signal processing algorithms. These confirm that the performance of OBS quantitatively agrees with predictions and also demonstrate that the use of compensation strategies improve detectability of damage.
Data-driven analysis for damage assessment has a large potential in structural health monitoring (SHM) systems, where sensors are permanently attached to the structure, enabling continuous and frequent measurements. In this contribution, we propose a machine learning (ML) approach for automated damage detection, based on an ML toolbox for industrial condition monitoring. The toolbox combines multiple complementary algorithms for feature extraction and selection and automatically chooses the best combination of methods for the dataset at hand. Here, this toolbox is applied to a guided wave-based SHM dataset for varying temperatures and damage locations, which is freely available on the Open Guided Waves platform. A classification rate of 96.2% is achieved, demonstrating reliable and automated damage detection. Moreover, the ability of the ML model to identify a damaged structure at untrained damage locations and temperatures is demonstrated.