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Paper des Monats
- ja (13)
Ziel des FuE-Vorhabens ist die Entwicklung, Aufbau und Validierung eines gasto-mographischen Messsystems basierend auf stationärer und mobiler Sensorik zum Emissionsmonitoring in kommunalen Kläranlagen. Die Gastomographie basiert hierbei im Wesentlichen auf, aus unterschiedlichen Sichtwinkeln aufgenommenen, integralen Konzentrationsmessungen, anhand derer eine Rekonstruktion der Gasverteilung erfolgt. Das FuE-Projekt kombiniert hierfür stationäre Sensornetzwerke mit luftgestützten und bodengebundenen Robotersystemen in einem System. Letztere werden mit Reflektoren und/oder Gasdetektoren ausgestattet. Hierfür werden Open-Path-Gasmesstechnik basierend auf Tunable Diode Laser Ab-sorption Spectroscopy (TDLAS, primär CH4 in ppm·m) und In-situ-Gassensorik (CH4, ppm) auf Basis von z.B. Infrarot eingesetzt. Dies sind zwei komplementäre Methoden der Gasmessung: Die In-situ-Gassensorik ermöglicht Punktmessungen, wohingegen TDLAS-Sensoren Gaskonzentrationen integral über offene Messstre-cken von bis zu 60 m gegen Oberflächen messen. Die In-situ-Gassensorik wird für Referenzmessungen und ggf. zur Erhöhung der Rekonstruktionsqualität zum Ein-satz kommen. Die wesentlichen Neuheiten des Projekts sind:
• 2D-Gastomographie auf Basis eines mit TDLAS-basierter Open-Path-Gasmesstechnik und Reflektoren ausgestatteten heterogenen Messsystems.
• CT-basierte Rekonstruktionsalgorithmen, adaptiert an die komplexen Rahmenbedingungen.
• Validierung des Messsystems anhand realer Messungen auf Kläranlagen.
Protection against terroristic or accidental scenarios in industrial settings requires suitable designs of structures to resist blast loads. Field testing as well as finite element simulations are among the techniques available to engineers in the understanding of the structural behavior against blast loading.
As blast testing of complex scenarios can be very resource intensive, tests are generally performed for simplified scenarios. Numerical tools can be used to model these scenarios to get better insight into blast loading, structural response, and the resulting damage to the structure. During the next steps, the simplified scenario is successively modified in numerical simulations to incorporate complexities that cannot be covered in blast testing experiments. One of the conditions for this approach to work is that the original simplified numerical simulation is valid. The scopes and challenges encountered in such a validation are the focus of this presentation/article.
A relatively ‘simple’ field test of a horizontal reinforced concrete (RC) slab subjected to blast loading is taken as an example for validation of the performance of numerical tools. The blast test incorporated various measurement techniques to quantify the blast load as well as the behavior of the RC slab. Blast load was measured using flush mounted piezoelectric pressure gauges, whereas acceleration sensors and fiber-optic sensor cables were used to characterize the dynamic behavior of the slab under blast loading. Additionally, damage characteristics were ascertained also using fiber optic sensing. The application of such measurement techniques, along with different numerical software available for the analysis of the scenario in question, demonstrate the scope of our contribution.
When it comes to the challenges, it begins with proper instrumentation of the test specimen followed by the data processing. For numerical modelling, geometric conditions with appropriate boundary constraints, physical conditions such as the configuration of the rebars, as well as material parameters add to this challenge. The issues of choosing appropriate material models and comparison of results with multiple software tools will be discussed. This discussion forms the basis for a coherent approach to technical-safety assessment of blast effects on structures in its broader sense.
Infrared thermography using a focused (spot or line) beam has proved to be effective for detection of surface breaking cracks on planar samples. In this work, we use the same principle, but applied to complex shaped components, like a rail section, a gear, and a gas turbine blade. We use a six-axis robot arm to move the sample in front of our thermographic setup. Several scanning paths and thermographic parameters are explored: scanning speed, density of points in each scanning slice, laser power and camera frame-rate. Additionally, we explore semi-automatic evaluation algorithms for crack detection, as well as 2D-to-3D registration of the found indications.
This technical note highlights the fact that CF-LIBS algorithms work in mole fractions, while results of spectrochemical analysis are usually reported in mass fractions or mass percent. Ignoring this difference and not converting mole fractions to mass fractions can lead to errors in reported concentrations determined by the CF-LIBS method and inadequate comparison of these concentrations with certified concentrations. Here, the key points of the CF-LIBS algorithm are reproduced and the formulae for converting a mole fraction to a mass fraction and vice versa are given. Several numerical examples are also given, which show that the greater the difference between the molar mass of an individual element in a sample and the average molar mass, the greater the discrepancy between the mole and mass fractions.
Automated Wall Thickness Evaluation for Turbine Blades Using Robot-Guided Ultrasonic Array Imaging
(2024)
Nondestructive testing has become an essential part of the maintenance of modern gas turbine blades and vanes since it provides an increase in both safety against critical failure and efficiency of operation. Targeted repairs of the blade’s airfoil require localized wall thickness information. This information, however, is hard to obtain by nondestructive testing due to the complex shapes of surfaces, cavities, and material characteristics. To address this problem, we introduce an automated nondestructive testing system that scans the part using an immersed ultrasonic array probe guided by a robot arm. For imaging, we adopt a two-step, surface-adaptive Total Focusing Method (TFM) approach.
For each test position, the TFM allows us to identify the outer surface, followed by calculating an adaptive image of the interior of the part, where the inner surface’s position and shape are obtained. To handle the large volumes of data, the surface features are automatically extracted from the TFM images using specialized image processing algorithms. Subsequently, the collection of 2D extracted surface data is merged and smoothed in 3D space to form the outer and inner surfaces, facilitating wall thickness evaluation. With this approach, representative zones on two gas turbine vanes were tested, and the reconstructed wall thickness values were evaluated via comparison with reference data from an optical scan. For the test zones on two turbine vanes, average errors ranging from 0.05 mm to 0.1 mm were identified, with a standard deviation of 0.06–0.16 mm.
Current capabilities for full-scale field testing are highly resource intensive. Reliable small-scale experiments are an effective alternative. Characterization of the dynamic response and damage of RC elements to scaled blast loads was investigated in scaled-down field experiments. Spatially resolved information on the dynamic structural response using distributed fiber optic acoustic sensing (DAS) and acceleration as well as blast loading by piezoelectric pressure sensors.
Rechargeable sodium–oxygen batteries (NaOBs) are receiving extensive research interests because of their advantages such as ultrahigh energy density and cost efficiency. However, the severe failure of Na metal anodes has impeded the commercial development of NaOBs. Herein, combining in situ synchrotron X-ray computed tomography (SXCT) and other complementary characterizations, a novel electro-chemo-mechanical failure mechanism of sodium metal anode in NaOBs is elucidated. It is visually showcased that the Na metal anodes involve a three-stage decay evolution of a porous Na reactive interphase layer (NRIL): from the initially dot-shaped voids evolved into the spindle-shaped voids and the eventually-developed ruptured cracks. The initiation of this three-stage evolution begins with chemical-resting and is exacerbated by further electrochemical cycling. From corrosion science and fracture mechanics, theoretical simulations suggest that the evolution of porous NRIL is driven by the concentrated stress at crack tips. The findings illustrate the importance of preventing electro-chemo-mechanical degradation of Na anodes in practically
rechargeable NaOBs.
Additive manufacturing of concrete structures is a novel and emerging technology. Freecontouring in civil engineering, which allows for entirely new designs, is a significant advantage. Inthe future, lower construction costs are expected with increased construction speeds and decreasingrequired materials and workers. However, architects and civil engineers rely on a certain quality ofexecution to fulfil construction standards. Although several techniques and approaches demonstratethe advantages, quality control during printing is highly challenging and rarely applied. Due to thecontinuous mixing process commonly used in 3D concrete printing, it is impossible to exclude varia-tions in the dry mixture or water content, and a test sample cannot be taken as a representative samplefor the whole structure. Although mortar properties vary only locally, a defect in one layer duringprinting could affect the entire integrity of the whole structure . Therefore, real-time process monitor-ing is required to record and document the printing process.At the Bundesanstalt für Materialforschung und -prüfung (BAM) a new test rig for the additive man-ufacturing of concrete is built. The primary purpose is measuring and monitoring the properties of amortar during the printing process.The following study investigates an approach for calculating yield stress and plastic viscosity based onexperimentally recorded pressure data. The calculations assume that fresh mortar behaves as a Bing-ham fluid and that the Buckingham-Reiner-equation is applicable. A test setup consisting of rigid pipeswith integrated pressure sensors at different positions is utilized.Monitoring the printing process with different sensors is crucial for the quality control of an ongoingprocess.
Die Pulskompression wird in der Radartechnik eingesetzt, um den Signal-Rausch-Abstand zu erhöhen. Das Ziel ist es die Entdeckungswahrscheinlichkeit eines Nutzsignals bei gleichbleibender Auflösung zu erhöhen. Durch den Einsatz von Barker Codes oder komplementären Golay Codes werden Sendesignale von Luftultraschallanwendungen pulscodiert. Dies ermöglicht in der zerstörungsfreien Prüfung die Inspektion von dickeren Bauteilen, da die Signalenergie durch zeitlich gestreckte Sendesignale bei gleicher Auflösung vergrößert wird.
In dieser Arbeit wird die Pulskompression durch die Einführung von unipolaren Sequenzen zur Pulscodierung für thermoakustische Ultraschallwandler ermöglicht. Der Signal-Rausch-Abstand wird in der Anwendung der Pulscodierung und anschließenden Filterung mit einem signalangepassten Filter in Luftultraschallmessungen mit dem thermoakustischen Wandler und Wandlern aus zellulärem Polypropylen erhöht.
For structural health monitoring systems or non-destructive testing, it is crucial to study the interactions of ultrasonic-guided waves with inhomogeneities or damage in structural components. Simulation of these interactions poses a challenge.
After the wave-damage interaction, the numerical model must reproduce features like mode conversion or wave scattering. Mathematically, damages are discontinuities in a computational domain, and each wave interacts differently because of the geometrical features. We propose a quadtree-based meshing in the current contribution to capture these geometrical characteristics.
This kind of discretisation approach requires special techniques to couple cells of different sizes since, after a quadtree decomposition, the problem of so-called hanging nodes may arise. Transition elements based on high-order transfinite shape functions are used to solve this issue. The advantage is that these elements allow the correct coupling of the cells while retaining a high-order interpolation. Moreover, the reuse of the dynamic stiffness matrices can be exploited based on the similarity of the cells. This procedure makes the approach very efficient.
Examples show the scattering characteristics of different guided wave modes after interacting with inhomogeneities and discontinuities in a plate.