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Eingeladener Vortrag
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We report on recent developments in the detection of surface breaking cracks using
flying laser spot thermography. Application of an infrared camera for mapping the
thermal radiation after excitation with a diode laser equipped with an optical scanner
allows us to examine a surface containing cracks in an entirely non-destructive,
contactless and fast way, without even moving the camera. We developed an efficient
and robust algorithm that can be applied directly to the recorded thermal sequences,
and that derives a single image containing all crack signatures. For this crack detection
technique, no specific synchronisation between laser and camera is required. Hence,
our approach is suitable for an upgrade of existing thermographic systems. The
feasibility of the proposed procedure is proven by testing an artificial test sample and a
piece of rail that comprises roll contact fatigue cracks and by comparing the results
with magnetic particle testing.
Active thermography is a nowadays widely used NDT method making use of thermal material properties for defect detection. Basically, the sample is heated and the resulting surface temperature is recorded by an IR camera. For laser thermography a laser is used to heat the sample locally. The resulting spherical heat flow allows the detection of voids in arbitrary orientation. In this work, a method is presented which is suitable for the quantitative characterization of depth and angle of surface cracks. The main idea is to evaluate the crack-caused asymmetries of the laser's thermal footprint. The heat is introduced at fixed reference positions relative to the crack. In this paper a data analysis procedure is presented which allows the crack depth and angle to be described by only two characteristic scalar parameters. By investigating artificial test specimens with spark eroded notches, the feasibility of this method is validated. Furthermore, the behavior of the characteristic parameters with variations of crack angle, depth and experimental conditions is studied systematically by FEM simulations, showing that these parameters are well behaved.
Spot welding is one of the most important technologies for joining sheet metal. While there are lot of approaches to non-destructive testing, quality assurance still mainly relies on welding parameter monitoring and destructive testing, leading to significant failure rates. In this paper an approach to spot weld testing using flash thermography is presented. The main focus of attention is on the identification of two typical error classes: stick welds and welds at the splash limit. Besides investigating the principal feasibility of thermography for zinc plated samples the results of a series test of spot welds joining 1 mm thick TRIP steel are shown. Based upon these results a statistical criterion is developed which allows a reliable classification of the named error classes.
False colour infrared (IR) thermography was performed on a sunny summer day in the Berlin Botanic Garden. The main interest focused on blossoms of different size, colours and shapes: disk-, bowl- and funnel-like anatomy demonstrating various modes of light absorption and heating-up during the day. Some of the flowers were phototropic or even solar tracking. Blossom temperatures ranged from 18.0 to 33.3 °C (mean 26.3 ± 2.5 °C, S.D., n = 37) at 21 °C air temperature. Several thermograms showed honey- and bumblebees also. In some cases the results are compared with those of a contact-free IR thermometry. One winter- and one late-spring-flowering plant are included in the overview.
Im Rahmen des Themenfeldprojektes „Process Monitoring of AM“ (ProMoAM) evaluiert die Bundesanstalt für Materialforschung und -Prüfung (BAM) gegenwärtig die Anwendbarkeit verschiedenster ZfP-Verfahren zur in-situ Prozessüberwachung in der additiven Fertigung (AM) von Metallen in Hinblick auf die Qualitätssicherung.
Einige der wichtigsten Messgrößen sind hierbei die Temperatur des Schmelzbades und die Abkühlrate, welche starken Einfluss auf das Gefüge und die Eigenspannung haben. Aufgrund der Zugänglichkeit zum Werkstück während des Bauprozesses bieten sich optische Verfahren zu Temperaturbestimmung an. Hierbei stellen jedoch u. a. die hohe Bandbreite der zu messenden Temperaturen, die Bestimmung der Emissivität und ihre Änderung bei Phasenübergängen der verwendeten Legierung große experimentelle Herausforderungen dar. Eine weitere Herausforderung stellt für die IR-Spektroskopie die Absorption durch das Schutzgas und weitere optische Elemente dar. Um diese auch in einem industriellen Umfeld kompensieren zu können, wurde eine Methode entwickelt, die das gemessene Spektrum bei der Verfestigung des Werkstoffes als Referenz nutzt. In diesem Beitrag wird die Anwendung dieser Methode für die IR-Spektrometrie als auch Thermografische Messungen beim Laser-Pulver-Auftragschweißen von 316L gezeigt, wobei beide Methoden weiterhin in Hinblick auf ihre individuellen Vor- und
Nachteile miteinander verglichen werden.
In this chapter, the current state-of-the-art of in situ monitoring and in situ NDE methods in additive manufacturing is summarized. The focus is set on methods, which are suitable for making statements about the quality and usability of a component currently being manufactured. This includes methods which can be used to determine state properties like temperature or density, other physical properties like electrical or thermal conductivity, the microstructure, the chemical composition, the actual geometry, or which enable the direct detection of defects like cracks, voids, delaminations, or inclusions. Thus, optical, thermographic, acoustic, and electromagnetic methods, as well as methods being suitable for investigating particle and fume emission are presented. The requirements of in situ monitoring methods with a focus on thermographic methods are discussed by considering different additive manufacturing processes like laser powder bed fusion (PBF-LB/M) and direct energy deposition (DED-LB/M). Examples of the successful implementation and applications of such monitoring methods at BAM are given. The in situ monitoring and NDE methods are compared against post-process NDE methods. The advantages and challenges of in situ methods concerning real-time data analysis and the application of AI algorithms are addressed and discussed.
The quality of additively manufactured components is significantly influenced by the process parameters used during production. Thus, sensors and measuring systems are already commercially available for process monitoring, at least in metal-based additive manufacturing. However, it is not yet possible to detect defects and inhomogeneities directly or indirectly during the building process. The aim of the project ProMoAM is to develop spectroscopic and non-destructive testing methods for the in-situ evaluation of the quality of additively manufactured metal components in laser- or arc-based AM processes. In addition to passive and active methods of thermography, this includes optical tomography, optical emission spectroscopy, eddy current testing, laminography (radiography), X-ray backscattering, particle emission spectroscopy and photoacoustic methods.
Additive manufacturing (AM) techniques have risen to prominence in many industrial sectors. This rapid success of AM is due to the freeform design, which offers enormous possibilities to the engineer, and to the reduction of waste material, which has both environmental and economic advantages. Even safety-critical parts are now being produced using AM. This enthusiastic penetration of AM in our daily life is not yet paralleled by a thorough characterization and understanding of the microstructure of materials and of the internal stresses of parts. The same holds for the understanding of the formation of defects during manufacturing. While simulation efforts are sprouting and some experimental techniques for on-line monitoring are available, still little is known about the propagation of defects throughout the life of a component (from powder to operando/service conditions). This Issue was aimed at collecting contributions about the advanced characterization of AM materials and components (especially at large-scale experimental facilities such as Synchrotron and Neutron sources), as well as efforts to liaise on-line process monitoring to the final product, and even to the component during operation. The goal was to give an overview of advances in the understanding of the impacts of microstructure and defects on component performance and life at several length scales of both defects and parts.
We present a systematic study on the performance of laser-thermography for the detection of surface cracks in metallic components. Scanning a metallic surface with laser causes local heating that is mapped simultaneously by an IR-camera and allows identifying cracks with sub-µm openings. The detectability, however, depends on a number of acquisition parameters (e.g. scanning speed, laser power, IR-camera resolution) that typically relate on each other. Most importantly, the detection-sensitivity of surface breaking cracks is given by a particular combination for the acquisition parameter values. As a result, this sensitivity is adaptable within wide ranges allowing the detection of cracks with openings ranging from 200 to 0.1 µm at testing speeds of 100 to 0.05 cm²/s. By examining artificial as well as fatigue cracks, we demonstrate that the method can be even applied to shiny surfaces with no need of pretreatments, which makes it an entirely contactless, remote and automatable NDT technique. A comparison with magnetic particle testing shows that laser-thermography has the potential to become a strong competitor to conventional surface inspection methods in the future.
Heat transfer modeling of local thermal excitation for surface crack detection and characterization
(2010)
In the presented paper the use of local excitation (laser beam) for crack detection and
characterization is simulated. As we could see, using the temperature differences between two
reference points was large enough to detect and characterize the crack, even for such small value of
laser power as 2 W. The influence of radiation and convection on the temperature difference was
negligible (about 0.1%). The influence of heat conduction, in case of crack with air, was very small
(about 3%). The main mechanism which influences the temperature differences between the
reference points is the heat conduction in steel. From the presented results one can see that
temperature differences are increasing with an increase of the crack depth or the crack length. Better
resolution and characterization of the crack depths and lengths should be achieved with increased
duration of heating time or the laser power. We could also see that the best position for the laser
spot to characterize the crack is the closest one. Also, comparison of 2D and 3D simulation results
for circular heat source used as local excitation mechanism had showed that only full 3D modelling
will allow accomplishing a quantitative level of comparison between experimental and simulation
results.
Monitoring of cracks in historic concrete structures using optical, thermal and acoustical methods
(2015)
Cracks are a major issue in the field of cultural heritage. In order to evaluate the significance of a crack, a long term monitoring of the damaged region is required. However, there is a lack of easy to operate tools for such monitoring measures. Therefore, new or existing methods for other applications have to be optimised for cultural heritage investigation. The paper describes the application of such crack observation methods on a historic concrete sculpture. Beside conventional methods, like mapping by hand and ultrasonic depth profiling, a novel tracking system is presented. Furthermore, the suitability of active thermography for the investigation of cracks was investigated. The results show promising prospects for these non-destructive techniques.
Additive manufacturing (AM) offers a range of novel applications. However, the manufacturing process is complex and the production of defect-free parts with high reliability and durability is still a challenge. Thermography is a valuable tool for process surveillance, especially in metal AM processes. The high process temperatures allow one to use cameras usually operating in the visible spectral range. Here, we compare the results of measurements during the manufacturing process of a commercial laser metal deposition setup using a mid-wavelength-IR camera with those from a visual spectrum high-speed camera with band pass filter in the near-IR range.
Quantification of impact damages in CFRP and GFRP structures with thermography and ultrasonics
(2018)
For the quantification of impact damage in CFRP and GFRP structures, first passive thermography measurements have been performed at the front and rear side of the test specimens during low velocity impact load. After loading, the damaged structures have been investigated non-destructively with active thermography with flash excitation and with step heating and with two different ultrasonic methods (phased array and air coupled ultrasonics). The damage sizes quantified with all methods are evaluated and compared. In addition, the depth of the greatest damage inside the different test specimens is analysed.
We present an in situ triple coupling of synchrotron X-ray diffraction with Raman spectroscopy, and thermography to study milling reactions in real time. This combination of methods allows a correlation of the structural evolution with temperature information. The temperature information is crucial for understanding both the thermodynamics and reaction kinetics. The reaction mechanisms of three prototypical mechanochemical syntheses, a cocrystal formation, a C@C bond formation (Knoevenagel condensation), and the formation
of a manganese-phosphonate, were elucidated. Trends in the temperature development during milling are identified. The heat of reaction and latent heat of crystallization of the product contribute to the overall temperature increase. A decrease in temperature occurs via release of, for example, water as a byproduct.
Solid and liquid intermediates are detected. The influence of the mechanical impact could be separated from temperature effects caused by the reaction.
In this paper shortwave infrared (SWIR) thermographic measurements of the manufacturing of thin single-line walls via laser metal deposition (LMD) are presented. As the thermographic camera is mounted fixed to the welding arm, an acceleration sensor was used to assist in reconstructing the spatial position from the predefined welding path. Hereby we could obtain data sets containing the size of the molten pool and the oxide covered areas as functions of the position in the workpiece. Furthermore, the influence of the acquisition wavelength onto the thermograms was investigated in a spectral range from 1250 nm to 1550 nm. All wavelengths turned out to be usable for the in-situ process monitoring of the LMD process. The longer wavelengths are shown to be beneficial for the lower temperature range, while shorter wavelengths show more details within the molten pool.