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Eingeladener Vortrag (wissenschaftliche Konferenzen)
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Additive manufacturing (AM) technologies, generally called 3D printing, are widely used because their use provides a high added value in manufacturing complex-shaped components and objects. Defects may occur within the components at different time of manufacturing, and in this regard, non-destructive techniques (NDT) represent a key tool for the quality control of AM components in many industrial fields, such as aerospace, oil and gas, and power industries. In this work, the capability of active thermography and eddy current techniques to detect real imposed defects that are representative of the laser powder bed fusion process has been investigated. A 3D complex shape of defects was revealed by a μCT investigation used as reference results for the other NDT methods. The study was focused on two different types of defects: porosities generated in keyhole mode as well as in lack of fusion mode. Different thermographic and eddy current measurements were carried out on AM samples, providing the capability to detect volumetric irregularly shaped defects using non-destructive methods.
The one-dimensional thermal quadrupole method is used to evaluate a pulsed thermography measurement at delaminations in a glass-fiber reinforced plastic plate quantitatively. The large-scale delaminations have been induced by tension overload and are air-filled and are usually located at the same depth as the notch bottom of a notch on the rear side. While classical evaluation methods like pulsed phase thermography and thermal Signal reconstruction are focused on the delamination depth only, the thermal quadrupole method determines spatially resolved two parameters for delaminations, delamination depth and local thermal resistance. Interestingly, lateral heat flows do not disturb this kind of depth evaluation.
Cooling-down of thermal thick probes after flash excitation - A measure for the real energy density?
(2015)
Though flash lamps are one of the most applied heat sources in the field of Thermographic Testing (TT) using active thermography, only little is known about the actually achieved energy input into test objects. In this paper, an easy to realize sensor concept is proposed and experimentally evaluated. The concept is based on the measurement of the surface temperature of a thermal thick probe after flash excitation. After considering the sensor concept with FEM simulations the experimental investigation of four materials (two polymer and two building materials) is described. It will be shown that a suited coating is essential for the realization of the sensor concept. The experimental results prove the suitability of black rigid PVC as the most promising material. Using a coated PVC sample the energy density of short laser pulses, similar to flashes of flash lamps, could be determined exactly with an estimated relative uncertainty of only a few percent.
This study evaluates whether subsurface features in rotor blades, mainly made of Glass Fibre Reinforced Plastics (GFRP), can generally be detected with ‘‘solar thermography”. First, the suitability of the sun is tested for acting as a heat source for applying active thermography on a 30 mm thick GFRP test specimen. Second, a defective rotor blade segment is inspected outdoors under ideal natural conditions using the sun as excitation source. Additionally, numerical FEM-simulations are performed and the comparability between experiment and simulation is evaluated for outdoor measurements.
The present study continues the work described in part I of this paper in evaluating a longterm-experiment, where a rotor blade segment of a wind turbine is exposed to the elements and thereby monitored with passive thermography. First, it is investigated whether subsurface features in rotor blades – mainly made of GFRP – can generally be detected with thermography from greater distances under favorable conditions. The suitability of the sun for acting as a heat source in applying active thermography has been tested in the previous study. In this study, the climatic influence on thermographic measurement is evaluated. It is demonstrated that there are favorable and unfavorable circumstances for imaging thermal contrasts which reflect inner structures and other subsurface features like potential defects. It turns out that solar radiation serves as a very effective heat source, but not at all times of day. Other environmental influences such as diurnal temperature variations also create temperature contrasts that permit conclusions on subsurface features. Particular scenarios are reconstructed with FEM-simulations in order to gain deeper insight into the driving mechanisms that produce the observed thermal contrasts. These investigations may help planning useful outdoor operations for inspecting rotor blades with thermography.
Lockin thermography is a well-suited method for the characterization of structures made of both metal and fiber reinforced plastic. In most cases, only phase images are analyzed, although the amplitude images might contain useful information as well. Thus, systematic studies of lockin thermography are presented, assessing amplitude and phase images for the detection and quantification of defects in isotropic (steel) and anisotropic (carbon fiber reinforced plastic) materials. Characterized defects are flat bottom holes with different diameters and various remaining wall thicknesses as well as crossed notches at different depths. The excitation frequency was varied while keeping the number of analyzed excitation periods nearly constant for each material. The data analysis was focused on the detectability of the defects both in the amplitude and phase images, including the determination of the signal-to-noise ratio and of the spatial resolution. As a result, the limits of defect detectability and spatial resolution are given for each material
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.
