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Organisationseinheit der BAM
- 8 Zerstörungsfreie Prüfung (276)
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- 9.3 Schweißtechnische Fertigungsverfahren (84)
- 4 Material und Umwelt (72)
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- 8.1 Sensorik, mess- und prüftechnische Verfahren (71)
- 5 Werkstofftechnik (63)
- 8.4 Akustische und elektromagnetische Verfahren (60)
Paper des Monats
- ja (1)
Das hochaktuelle Thema der Integration und Wiederverwendung von Wissen und Daten aus Herstellung, Bearbeitung und Charakterisierung von Materialien ('Digitalisierung von Materialien') wird in den Projekten Innovationsplattform MaterialDigital (PMD, materialdigital.de) und Materials-open-Lab (Mat-o-Lab, matolab.org) adressiert. In diesem Beitrag werden die Weiterentwicklungen in diesen Projekten hinsichtlich der Speicherung von Zugversuchsdaten gemäß einer normenkonformen (DIN EN ISO 6892-1:2019-11) ontologischen Repräsentation vorgestellt. Das umfasst den Weg von der Entwicklung einer Ontologie nach Norm, der Konvertierung von Daten aus Standardtests in das interoperable RDF-Format bis hin zur Verknüpfung von Ontologie und Daten. Letztendlich können die entsprechenden Daten in einem Triple Store abgelegt und abgefragt werden.
Komponenten von Fahrrädern werden im Betrieb vorwiegend schwingend beansprucht. Typische Werkstoffe sind Stahl, Aluminiumlegierungen, Messing, CFK und thermoplastische Kunststoffe. Da es sich, unabhängig von der Preiskategorie, um konstruktiven Leichtbau handelt, werden einige Bauteile betriebsfest mehr oder weniger weit oberhalb der Dauerfestigkeit ausgelegt. Die im normalen Betrieb auftretenden Schäden sind daher weit überwiegend Schwingbrüche. Andere Schadensmechanismen wie z.B. Korrosion spielen quantitativ eine untergeordnete Rolle. Schwingbrüche treten nach einer Periode unbemerkten Risswachstums oft ohne Vorwarnung und ohne makroskopische Verformung auf. Im Falle von sicherheitsrelevanten Komponenten wie Rahmen, Gabeln, Lenkern, Sattelstützen, Kurbelarmen oder Pedalen kann dies zu erheblichen Personenschäden führen, die den Wert des ursächlichen Bauteilschadens weit überschreiten.
Über einen langjährigen Zeitraum wurden gebrochene Komponenten aus dem Alltag und aus Gerichtsverfahren analysiert. Das Hauptaugenmerk lag hierbei auf der fraktographischen Analyse, teilweise wurden die zu Grunde liegenden Schadensursachen ermittelt. Einflussfaktoren sind beispielsweise konstruktive Kerben an ungünstigen Stellen, aber auch Werkstoffwahl und Fertigungsqualität spielen eine Rolle. In den meisten Fällen wurde jedoch die konstruktive Lebensdauer überschritten. Diese wird praktisch nie mitgeteilt, und eine wiederkehrende Prüfung sicherheitsrelevanter Bauteile findet nicht statt.
Im Sinne der Vermeidung von Schäden und Unfällen könnte darauf hingewirkt werden, für sicherheitsrelevante Komponenten Lebensdauern besser abzuschätzen und von der Laufleistung abhängige Sichtprüfungen zu empfehlen.
Understanding on how a machine learning model interprets data is a crucial step to verify its reliability and avoid overfitting. While the focus of the scientific community is nowadays orientated towards deep learning approaches, which are considered as black box approaches, this work presents a toolbox that is based on complementary methods of feature extraction and selection, where the classification decisions of the model are transparent and can be physically interpreted. On the example of guided wave benchmark data from the open guided waves platform, where delamination defects were simulated at multiple positions on a carbon fiber reinforced plastic plate under varying temperature conditions, the authors could identify suitable frequencies for further investigations and experiments. Furthermore, the authors presented a realistic validation scenario which ensures that the machine learning model learns global damage characteristics rather than position specific characteristics.
Hochfeste Feinkornbaustähle verfügen über großes Potenzial für gewichtsoptimierte, effiziente Strukturen in vielen modernen Stahlkonstruktion. Weitere Effizienzsteigerungen können durch additives Fertigen sowie bionische Bauweisen erreicht werden. Hochfeste Zusatzwerkstoffe für additives MSG-Schweißen (engl.: Wire Arc Additive Manufacturing, WAAM) sind bereits von den Schweißzusatzherstellern lieferbar. Eine breite industrielle Anwendung insbesondere für KMU ist aufgrund fehlender quantitativer Erkenntnisse und Richtlinien bezüglich schweißbedingter Beanspruchungen und Bauteilsicherheit während der Herstellung und des Betriebs derzeit stark limitiert. In einem gemeinsamen Forschungsprojekt (FOSTA-P1380/IGF21162BG) der BAM und der TU Chemnitz werden daher die mit Eigenspannungsausbildung und der Gefahr einer Kaltrissbildung verbundenen prozess- und werkstoffbedingten sowie konstruktiven Einflüsse beim WAAM hochfester Stähle untersucht. Der vorliegende Beitrag fokussiert die Analyse der Auswirkungen von Schweißwärmeführung und Design der WAAM-Bauteile auf die Abkühlbedingungen, Gefüge, mechanisch-technologischen Eigenschaften und Eigenspannungen. Hierfür werden geometrisch definierte Probenkörper (Hohlquader) vollautomatisiert mit einem speziellen, hochfesten WAAM-Massivdraht (Streckgrenze >790 MPa) geschweißt. Die Wärmeführung und Probenabmessungen werden innerhalb eines statistischen Versuchsplans variiert. Die Schweißwärmeführung wird dabei so eingestellt, dass die t8/5-Abkühlzeiten im empfohlenen Verarbeitungsbereich (ca. 5 s bis 20 s) sichergestellt sind. Hierzu ließen sich über zusätzliche thermo-physikalische Umformsimulationen mittels Dilatometer die komplexen Wärmezyklen abbilden und die resultierende Zugfestigkeit des Schweißgutes bestimmen. Das WAAM-Schweißen komplexer Geometrien mit variierenden Schweißwärmeführungen und geometrischen Verhältnissen bzw. Wanddicken bedingt neben den Auswirkungen auf die Abkühlbedingungen, Abkühlzeiten und Gefüge deutliche Einflüsse auf die konstruktiven Steifigkeitsverhältnisse beim Schweißen. Es zeigen sich anhand der Schweißexperimente signifikante Auswirkungen durch Probenskalierung und Wärmeeinbringung auf die resultierenden lokalen Eigenspannungen. Die Folge können ungünstige Bauteileigenschaften und risskritische Zugeigenspannungen sein.
Multielement-Legierungen (MPEA – multiple pricipal element alloys) stellen eine neue Klasse von Werkstoffen dar, die aus mindestens drei äquiatomaren Legierungselementen mit jeweils einem Gehalt von 5–35 Atom-% bestehen. Somit unterscheidet sich das Legierungskonzept fundamental von konventionellen bspw. Stahl- oder Al-basierten Legierungen. In jüngster Zeit lag der Schwerpunkt auf dem Legierungs-Design der MPEA und der Überprüfung bzw. Erreichung der gewünschten Eigenschaften bzw. -kombinationen. Hierzu werden die egierungselemente gezielt ausgewählt und die Mikrostrukturen ein- und zum Teil auch mehrphasig eingestellt. Ziel sind hochinnovative MPEA mit angepassten Eigenschaften für die industrielle Anwendung. Dabei sollen insbesondere die bei konventionellen Legierungen wesentlichen Zielkonflikte, wie bspw. der Trade-off zwischen Festigkeit und Duktilität, überwunden werden. Darüber hinaus sind mechanische Eigenschaften bei sehr hohen sowie kryogenen Temperaturen bei gleichzeitig höchster Korrosionsbeständigkeit von hohem Interesse. Die Herstellung von Bauteilen erfordert dazu werkstoff- und beanspruchungsgerechte Füge- bzw. Schweißverfahren. Der Schweißeignung von MPEA wurde bis Ende 2021 nur äußert wenig Aufmerksamkeit zuteil. Die Auswirkungen durch Schweißprozesse auf die Metallurgie und die gewünschten Eigenschaften sind bisher kaum bekannt und limitieren die potenzielle Anwendbarkeit als Funktions- oder Konstruktionswerkstoffe.
In einem interdisziplinären BAM-Forschungsprojekt werden aktuell grundlegende Untersuchungen zur Schweißverarbeitung und resultierender Mikrostruktur-Anwendungseigenschafts-Beziehung verschiedener MPEA durchgeführt. Insbesondere Wärmeeinflusszone und Schweißgut sind geprägt durch eine Mikrostruktur, die aus Ungleichgewichtszuständen resultiert. Im Falle von MPEA wurde dies bisher nicht systematisch untersucht. Dazu erfolgte im Rahmen des Projektes eine umfassende Literaturauswertung zum Schweißen von MPEA und Zusammenfassung in einer umfassenden, systematischen Datenbasis. Aus diesem Grund sollen in der vorliegenden Studie die bisher bedeutsamsten Erkenntnisse zur Schweißbarkeit von MPEA systematisch nach MPEA-Typ und Schweißverfahren geordnet und mit eigenen aktuellen Forschungsergebnissen verglichen werden. Durch WIG- und Rührreibschweißversuche an den MPEA-Systemen CoCrNiFeMn bzw. CoCrNi konnten im Projektverlauf bereits wesentliche Fragestellungen beantwortet werden. Dazu zählen Auftreten bzw. Verhinderung intermetallischer Phasen/Seigerungen oder deren Auswirkung auf die Eigenschaften der Schweißverbindung (bspw. Festigkeit oder Korrosionsbeständigkeit).
Die lichtbogenbasierte, additive Fertigung ist dank hoher erreichbarer Aufbauraten und nahezu uneingeschränktem Bauraum zur Fertigung großvolumiger Bauteile prädestiniert. Die Kombination etablierter Maschinenkomponenten aus Robotertechnik, Schweißtechnik und Sensorik ermöglicht den präzisen schichtweisen Materialauftrag. Die Wirkmechanismen zwischen Prozessparametern und den daraus resultierenden mechanisch-technologischen Eigenschaften der additiv gefertigten Bauteile stellen eine Herausforderung dar. Dies gilt insbesondere auch für dickwandige Bauteile. Bei der Fertigung von Bauteilen aus höherfesten Al-Mg-Si-Aluminiumlegierungen ist aufgrund der hohen Anfälligkeit für Erstarrungsrisse und der Neigung zu wasserstoffinduzierter Porosität im besonderen Maße auf das Temperaturregime und die gewählte Aufbaustrategie zu achten.
Der Einfluss der Prozessparameter auf die Bauteilqualität wurde durch die Analyse der Größe und Verteilung von Poren sowie der resultierenden Festigkeit untersucht. Darüber hinaus wurde der Einfluss einer Wärmenachbehandlungsstrategien auf das Festigkeitsverhalten analysiert. Es konnte gezeigt werden, dass dickwandige Strukturen aus höherfesten Al-Mg-Si-Aluminiumlegierungen mit mechanischen Kennwerten im Bereich des Referenzmaterials mittels MSGLichtbogenverfahren additiv gefertigt werden können.
Hochfeste Feinkornbaustähle verfügen über ein großes Potenzial für gewichtsoptimierte, effiziente Strukturen in vielen modernen Stahlkonstruktion. Weitere Effizienzsteigerungen können durch additives Fertigen sowie bionische Bauweisen erreicht werden. Kommerzielle hochfeste Zusatzwerkstoffe für additives MSG-Schweißen (engl.: Wire Arc Additive Manufacturing, WAAM) sind bereits von den Schweißzusatzherstellern lieferbar. Derzeit ist jedoch eine breite industrielle Anwendung insbesondere für KMU aufgrund fehlender quantitativer Erkenntnisse und Richtlinien bezüglich schweißbedingter Beanspruchungen und Bauteilsicherheit während der Herstellung und des Betriebs stark limitiert. In einem gemeinsamen Forschungsprojekt (FOSTA-P1380/IGF21162BG) der BAM und der TU Chemnitz werden die mit Eigenspannungsausbildung und der Gefahr einer Kaltrissbildung verbundenen prozess- und werkstoffbedingten sowie konstruktiven Einflüsse untersucht. Im Fokus dieser Analysen steht die Bestimmung der Wechselwirkungen zwischen WAAM-Prozessparametern bzw. der Wärmeführung auf das Gefüge und die Eigenspannungen. Hierfür werden Referenzproben als offene Hohlquader mit definierten Abmessungen vollautomatisiert mit einem speziellen, hochfesten WAAM-Massivdraht (Streckgrenze >790 MPa) geschweißt. Die gezielte Einstellung der geometrischen Eigenschaften erfolgt durch Schweißparameter und Nahtaufbau bei ca. 4 kg/h mittlerer Abschmelzleistung. Die Wärmeführung wird innerhalb eines statistischen Versuchsplanes mittels Streckenenergie (200 kJ/m bis 650 kJ/m) und Zwischenlagentemperatur (100 °C bis 300 °C) so variiert, dass die t8/5-Abkühlzeiten dem empfohlenen Verarbeitungsbereich entsprechen (ca. 5 s bis 20 s). Ziel ist es bei konstanten geometrisch-konstruktiven Randbedingungen, den Einfluss der Wärmeführung auf Gefüge und resultierende Eigenspannungen zu analysieren. Für die Streckenenergie können neben den Gefügeeinflüssen aufgrund der resultierenden Abkühlzeit deutliche Effekte insbesondere auf die lokalen Eigenspannungen im Bauteil belegt werden. Das Schweißen mit zu hoher Wärmeeinbringung bzw. Abschmelzleistung kann zu ungünstigen Gefüge- und Bauteileigenschaften führen, gleichzeitig jedoch niedrigere Zugeigenspannungsniveaus bewirken. Solche komplexen Wechselwirkungen gilt es letztlich mit diesen Untersuchungen zu klären, um leicht anwendbare Verarbeitungsempfehlungen und Normvorgaben für ein wirtschaftliches, anforderungsgerechtes und risssicheres WAAM von hochfesten Stählen den Anwendern zur Verfügung zu stellen.
Eine nachhaltige und ressourceneffiziente Fertigung und Errichtung von Windenergieanlagen, sowohl auf See als auch an Land, erfordert zunehmend den Einsatz moderner hochfester Feinkornbaustähle. Werden nach dem Schweißen dieser hochfesten Konstruktionen unzulässige Defekte detektiert, sind nach geltenden Verarbeitungsrichtlinien die defekten Bereiche durch lokales Ausfugen und anschließendes Schweißen zu reparieren. Fehlende Informationen zu adäquaten Reparaturkonzepten in den Regelwerken bedingen oftmals eine unzureichende Berücksichtigung dabei auftretender zusätzlicher Beanspruchungen durch die erhöhte Schrumpfbehinderung der Ausfugenuten. Zusätzlich haben die ausführenden Betriebe vielfach kaum Kenntnis über die Degradation angrenzender Gefüge durch thermische Ausfugeprozesse und erneutes Schweißen, die in diesem Zusammenhang besonders bei den hochfesten Stählen als kritisch anzusehen sind. Das aktuelle Forschungsvorhaben der BAM (FOSTA P1311/IGF-Nr.20162N) fokussiert hierfür systematisch bauteilrelevante Untersuchungen zu den schweißbedingten Beanspruchungen und Gefügeveränderungen bei der Reparatur von hochfesten Schweißverbindungen. Wesentlich sind hierbei der Einfluss der Schrumpfbehinderung, der Wärmeführung beim Schweißen und Ausfugen sowie der Reparaturzyklenanzahl und die metallurgischen Aspekte bei den hochfesten Güten S500MLO für zukünftige Offshore-Anwendungen und S960QL für aktuelle Mobilkrananwendungen. Aufbauend auf einigen Studien zur schweißbedingten Beanspruchung hochfester Stähle zeigt der vorliegende Beitrag die Identifikation geeigneter Probengeometrien und Schweißdetails mittels numerischer und experimenteller Analysen. Dadurch wird die Übertragbarkeit der vorgestellten Schweißexperimente und Ergebnisse hinsichtlich der resultierenden Schweißeigenspannungen auf reale Reparaturfälle im Bereich des hochfesten Stahlbaus sichergestellt. Es zeigt sich in Übereinstimmung mit früheren Ergebnissen eine signifikante Erhöhung der Beanspruchungen an den variierten schlitzförmigen Prüfnähten. Das Eigenspannungsniveau sowohl im Schweißgut als auch in der WEZ korreliert mit dem Einspanngrad. Mit dem Ziel beanspruchungs- und werkstoffgerechte Reparaturkonzepte zu erarbeiten, sind zum einen geringere Wärmeinbringungen, besonders durch niedrige Zwischenlagentemperaturen und Einspannbedingungen anzustreben, um hohe Beanspruchungen und kritische Gefügedegradationen im Reparaturbereich zu vermeiden. Dies wird durch systematische Untersuchungen zum Ausfugen und Schweißen sowie letztlich dem Transfer von Verarbeitungsempfehlungen für die Anwender und Richtlinien erreicht.
Für Komponenten im Turbinen- oder Anlagenbau werden aufgrund ihrer Eigenschaften häufig Kobalt-Chrom-Legierungen verwendet. Diese weisen eine hohe Korrosionsbeständigkeit und hohen Verschleißwiederstand auf. Aufgrund der komplexen Strukturen und dem Bestreben nach Ressourceneffizienz wird zur Herstellung der Komponenten die additive Fertigung verwendet. Hierbei sind hinsichtlich der Inhomogenität und Anisotropie der Gefüge und deren Eigenschaften weitere Kenntnisse notwendig. Bei den vorliegenden Belastungen liegt ein erhöhter Anspruch an die Oberflächenintegrität vor, welcher durch komplementären Einsatz von additiven und abtragenden Fertigungsschritten sichergestellt wird. Dabei sind gerade Co-Cr-Legierungen wegen der niedrigen Wärmeleitfähigkeit verbunden mit hoher Festigkeit und Zähigkeit äußerst herausfordernd mit Blick auf eine wirtschaftliche Zerspanung mit geometrisch bestimmter Schneide. Ausgehend von dieser Problemstellung erfolgt im Zuge eines Gemeinschaftsvorhabens des ISAF in Kooperation mit der BAM eine gezielte Beeinflussung des Gefüges. Ziel des Projektes ist die Zusammenhänge zwischen verschiedenen Legierungsmodifikationen, der entstehenden Gefügemorphologie und den Zerspanungseigenschaften von Co- Cr-Legierungen für die additive Fertigung mittels PTA darzustellen. Der Fokus liegt auf dem Beheben der bestehenden Nachteile bei gleichzeitigem Aufrechthalten der besonderen Eigenschaften der Legierung. Durch das Hinzulegieren von variierenden Gehalten von Zirkonium und Hafnium wird die Gefügeveränderung eingestellt. Es hat sich gezeigt, dass Hafnium als zusätzliches Legierungselement einen deutlichen Einfluss auf die Gefügemorphologie hat. Darüber hinaus wird die Auswirkung der Legierungsmodifikation auf die Härte und die Zerspanbarkeit dargestellt.
Hochfeste Feinkornbaustähle verfügen über ein großes Potenzial für gewichtsoptimierte, effiziente Strukturen in vielen modernen Stahlkonstruktion. Weitere Effizienzsteigerungen können durch additives Fertigen sowie bionische Bauweisen erreicht werden. Kommerzielle hochfeste Zusatzwerkstoffe für additives MSG-Schweißen (engl.: Wire Arc Additive Manufacturing, WAAM) sind bereits von den Schweißzusatzherstellern lieferbar. Derzeit ist jedoch eine breite industrielle Anwendung insbesondere für KMU aufgrund fehlender quantitativer Erkenntnisse und Richtlinien bezüglich schweißbedingter Beanspruchungen und Bauteilsicherheit während der Herstellung und des Betriebs stark limitiert. In einem gemeinsamen Forschungsprojekt (FOSTA-P1380/IGF21162BG) der BAM und der TU Chemnitz werden die mit Eigenspannungsausbildung und der Gefahr einer Kaltrissbildung verbundenen prozess- und werkstoffbedingten sowie konstruktiven Einflüsse untersucht. Im Fokus dieser Analysen steht die Bestimmung der Wechselwirkungen zwischen WAAM-Prozessparametern bzw. der Wärmeführung auf das Gefüge und die Eigenspannungen. Hierfür werden Referenzproben als offene Hohlquader mit definierten Abmessungen vollautomatisiert mit einem speziellen, hochfesten WAAM-Massivdraht (Streckgrenze >790 MPa) geschweißt. Die gezielte Einstellung der geometrischen Eigenschaften erfolgt durch Schweißparameter und Nahtaufbau bei ca. 4 kg/h mittlerer Abschmelzleistung. Die Wärmeführung wird innerhalb eines statistischen Versuchsplanes mittels Streckenenergie (200 kJ/m bis 650 kJ/m) und Zwischenlagentemperatur (100 °C bis 300 °C) so variiert, dass die t8/5-Abkühlzeiten dem empfohlenen Verarbeitungsbereich entsprechen (ca. 5 s bis 20 s). Ziel ist es bei konstanten geometrisch-konstruktiven Randbedingungen, den Einfluss der Wärmeführung auf Gefüge und resultierende Eigenspannungen zu analysieren. Darüber hinaus erfolgt die Bestimmung des Einflusses der t8/5-Abkühlzeit auf die mechanisch-technologischen Eigenschaften des speziellen, hochfesten WAAM-Massivdrahts mithilfe von Dilatometeranalysen. Für die Streckenenergie können neben den Gefügeeinflüssen aufgrund der resultierenden Abkühlzeit deutliche Effekte insbesondere auf die lokalen Eigenspannungen im Bauteil belegt werden. Das Schweißen mit zu hoher Wärmeeinbringung bzw. Abschmelzleistung kann zu ungünstigen Gefüge- und Bauteileigenschaften führen, gleichzeitig jedoch niedrigere Zugeigenspannungsniveaus bewirken. Die Dilatometeranalysen zeigen für den untersuchten WAAM-Schweißzusatzwerkstoff eine großes t8/5-Zeitfenster mit einer vergleichsweise geringen Abnahme der Zugfestigkeit mit zunehmender t8/5-Abkühlzeit. Solche komplexen Wechselwirkungen gilt es letztlich mit diesen Untersuchungen zu klären, um leicht anwendbare Verarbeitungsempfehlungen und Normvorgaben für ein wirtschaftliches, anforderungsgerechtes und risssicheres WAAM von hochfesten Stählen den Anwendern zur Verfügung zu stellen.
Die additive Verarbeitung hochfester Feinkornbaustähle mittels Wire Arc Additive Manufacturing (WAAM) ist ein komplexes, aber zugleich auch effizientes Verfahren, bei dem Werkstoff, Bauteilgeometrie und Schweißprozess gezielt aufeinander abgestimmt sein müssen. Ziel dieser Studie war es, einen Zusammenhang zwischen den Prozessparametern und der generierten Schichtgeometrie zu ermitteln. Dazu wurden definierte Referenzkörper mit einem robotergestützten Schweißsystem additiv gefertigt und hinsichtlich Schichthöhe, Wandstärke und Mikrostruktur analysiert. Fokus der Untersuchung waren sowohl konventionelle als auch für die WAAM-Fertigung speziell entwickelte hochfeste Schweißzusatzwerkstoffe. Die geometrischen Eigenschaften additiv gefertigter Bauteile lassen sich insbesondere durch die Faktoren Drahtvorschubgeschwindigkeit und Schweißgeschwindigkeit gezielt einstellen. Jedoch können diese Parameter nicht beliebig variiert werden, auch aufgrund der rheologischen Eigenschaften der Zusatzwerkstoffe. Zu hohe Streckenenergien führen zu lokalen Überhitzungen und Fehlstellen in der generierten Schicht. Undefinierte Fließ- und Erstarrungsvorgänge im überhitzten Bereich erschweren die maßhaltige Fertigung. Deshalb wird bei speziellen WAAM-Schweißdrähten das Fließverhalten gezielt modifiziert, sodass es über einen größeren Temperaturbereich hinweg konstant ist. Erst die Kenntnis über die komplexen Zusammenhänge zwischen den Prozessparametern und der Bauteilgeometrie ermöglicht die Erzeugung exakter Schichtmodelle für die additive Fertigung. Dies bildet die Grundlage für die Bearbeitung weiterer Fragestellungen auf dem Gebiet der additiven Fertigung mit hochfesten Zusatzwerkstoffen und insbesondere deren Anwendung in modernen hochfesten Bauteilen.
With 8% of man-made CO2 emissions, cement production is an important driver of the climate crisis. By using alkali-activated binders, part of the energy-intensive clinker production process can be dispensed. However, as numerous raw materials are involved in the manufacturing process here, the complexity of the materials increases by orders of magnitude. Finding a properly balanced binder formulation is like looking for a needle in a haystack. We have shown for the first time that artificial intelligence (AI)-based optimization of alkali-activated binder formulations can significantly accelerate research.
The "Sequential Learning App for Materials Discovery" (SLAMD) aims to accelerate practice transfer. With SLAMD, materials scientists have low-threshold access to AI through interactive and intuitive user interfaces. The value added by AI can be determined directly. For example, the CO2 emissions saved per ton of cement can be determined for each development cycle: the more efficient the AI optimization, the greater the savings.
Our material database already includes more than 120,000 data points of alternative binders and is constantly being expanded with new parameters. We are currently driving the enrichment of the data with a life cycle analysis of the building materials.
Based on a case study we show how intuitive access to AI can drive the adoption of techniques that make a real contribution to the development of resource-efficient and sustainable building materials of the future and make it easy to identify when classical experiments are more efficient.
In vielen Anwendungen werden aufgrund zunehmender Anforderungen an den Widerstand gegenüber hohen, kombinierten mechanischen, tribologischen, thermischen und korrosiven Beanspruchungen Hochleistungslegierungen eingesetzt. Den vielfach komplexen Bauteilstrukturen, herausfordernden Fertigungseigenschaften und der Erhöhung der Ressourceneffizienz lässt sich heute mit der additiven Fertigung (AM) begegnen, dem oftmals noch unzureichende Kenntnisse über die resultierende Homogenität und Anisotropie der speziellen Gefüge und den damit verbundenen Eigenschaften entgegensteht. Viele Anwendungen benötigen zudem definierte Oberflächen mit hohen Anforderungen an die Oberflächenintegrität, dem durch komplementären Einsatz von additiven und abtragenden Fertigungsschritten Rechnung getragen wird. Hochleistungslegierungen auf der Basis von Nickel oder Kobalt sind infolge der niedrigen Wärmeleitfähigkeit verbunden mit hoher Festigkeit und Zähigkeit äußerst herausfordernd mit Blick auf eine wirtschaftliche Zerspanung mit geometrisch bestimmter Schneide. Ein Vorhaben (IGF-Nr. 20.979 N/DVS-Nr. 1.3211) der BAM und TU Clausthal/ISAF befasst sich mit der Lösung dieser Problemstellung durch gezielte Beeinflussung des Gefüges mittels Modifikation der Schweißzusatzwerkstoffe und den Einsatz des ultraschallunterstützten Fräsens (US), bei gleichzeitiger Sicherstellung der geforderten Eigenschaften der untersuchten Werkstoffe. Im vorliegenden Beitrag werden für die beiden untersuchten FeNi- und CoCr-Legierungen wesentliche Zusammenhänge zwischen verschiedenen Legierungsmodifikationen, der entstehenden Gefügemorphologie und den Zerspanungseigenschaften von mittels PTA additiv gefertigter Proben dargestellt. Hierbei ließen sich Ti, Zr und Hf pulvermetallurgisch zu den jeweiligen Ausgangsschweißzusätzen hinzulegieren.
Usually, geometric irregularities are considered as the main cause of ground vibrations from trains. A varying stiffness of the track, the track support and the soil can also generate ground vibrations. The regular stiffness variation of the track on and between the sleepers results in a deterministic dynamic axle load. The random stiffness variation of the track support yields also dynamic axle loads which are generated by the acceleration of the unsprung mass (from the varying wheel displacements under the static axle load). The random stiffness variation has a second effect. The pulses from the passage of the static axle loads are superposed regularly to the quasi-static response, but also irregularly to yield a “scattered” part of the axle pulses. The same holds for a random variation of the soil stiffness. All these effects of stiffness variations have been calculated by wavenumber-domain multi-beam track models, a random finite-element soil model and the superposition of axle impulses in a stochastic simulation. The results are confronted with many measurements at different sites. It is concluded that the stiffness variation of the track and the soil generate an important ground vibration component near railway lines.
A simple and fast prediction scheme is presented for train-induced ground and building vibrations. For the emission, finite-element boundary-element or multiple-beam-on-continuous-soil models of the track have been analysed and approximated by faster track-on-Winkler-soil models. The vehicle-track interaction due to irregularities yields the excitation forces. For the transmission of waves in the soil, the wavenumber integral of the compliance of layered soils has been evaluated. The calculation time is reduced for the prediction by using the solution of a homogeneous half-space with a frequency-dependent wave velocity (the dispersion) of the soil. For the immision, many 2 and 3-dimenisonal finite-element building models have been investigated, and a good approximation has been established by a 1-dimensional soil-wall-floor model. In addition, the axle sequence of the train, the quasi-static and the “scattered” response of the soil, and the wave propagation from a tunnel to a pile foundation of a building have been included.
Vibration measurements have many causes and many technical and natural sources. Problems can sometimes be solved by short-term measurements, but in many cases, a long-term measurement is necessary. In long-term measurements of days, weeks, months and even years, it is easy to collect a huge quantity of raw data, but at the end, the post-processing of these data can be exhausting (for example one-year vibration data of a wind energy tower). A software has been developed which con-sists of measuring and evaluation routines where the measuring routines can operate different meas-uring systems and different measuring cards. The main advantage of this software is the fact that the interesting evaluations can be integrated in the measuring process so that the characteristics of the vibration can be extracted without storing all the raw data. Only important time segments are stored, for example train passages. The overall concept of the software and the main evaluation routines will be described in some details. Examples of our measurement experience will illustrate the capabilities of the software. 1) Surveying construction work in nearby sensitive buildings (for example an old wind tunnel), including a stable alarm system and meaningful vibration limits. 2) Prediction of train-induced vibration for a planned building to prevent annoyance and to improve the building design. 3) Modal analysis and long term measurements of several single- or multi-span, concrete or steel bridges 4) Modal and wave analysis of coupled floors in a historical building (“Neues Palais” at Potsdam). 5) Soil properties of various measurement sites (different routines to evaluate the dispersion). Moreover, from many projects, amplitudes, frequencies, and attenuation laws have been collected and analysed for the different sources such as vibratory or impact pile driving and ground compaction, demolition work with different machines, blasting in quarries and in tunnel works, bomb and mine clearing.
This work focuses on the design and fabrication of low-cost and fast-response of an electronic nose (E-nose) based on semiconductor gas sensors, for discriminating some synthetic gases such as ammonia (NH3), ethanol (C2H5OH), and hydrogen sulfide (H2S). Additionally, the capability of separating different concentration levels of each considered gases was checked. Dataset treatment of E-nose by using Principal Component Analysis (PCA) showed a good discrimination of the different synthetic gases. Furthermore, perfect classification was reached of different concentration levels of the analysed gases by using Discriminant Function Analysis (DFA). In the light of these results, it could be stated that the developed E-nose system constitutes an inexpensive, rapid, simple to use, and efficient tool for synthetic gases detection.
In non-destructive testing and structural health monitoring with ultrasonic waves, the quantification of damage in components is one of the main tasks. In many shell-like structures, such as plates, pipes, or laminate components, ultrasonic waves propagate as guided waves. Although guided waves enable the testing of large areas, their multimodal and dispersive properties make it challenging to analyze signals. So, there is a need for more advanced algorithms to handle these properties, especially when reconstructing damage position and geometry.
The reconstruction can be formulated as an inverse problem where the measured signals are fitted with a simulative forward model. Due to the small wavelength of ultrasonic waves, classic forward models based on, e.g., the Finite Element Method are computationally intensive. In contrast, the authors use the semi-analytical Scaled Boundary Finite Element Method (SBFEM) to reduce the computational effort. The SBFEM approximates arbitrary long, undamaged parts of the structure with only a few degrees of freedom.
This contribution summarizes a general inverse procedure based on algorithmic differentiation in combination with the SBFEM. Results are presented for damaged 2D cross-sectional models of waveguides. These results include an analysis of the robustness of the proposed algorithms against noise.
An accurate and efficient description of the spatial distribution of laser energy is a crucial factor for the modeling of laser material processing, e.g., laser welding, laser cutting, or laser-based additive manufacturing. In this study, a 3D heat transfer and fluid flow model coupled with the volume-of-fluid algorithm for free surface tracking is developed for the simulation of molten pool dynamics in high-power laser beam welding. The underlying laser-material interactions, i.e., the multiple reflections and Fresnel absorption, are considered by a ray-tracing method. Two strategies of free surface reconstruction used in the ray-tracing method are investigated: a typical piecewise linear interface calculation (PLIC)-based method and a novel localized Level-Set method. The PLIC-based method is discrete, resulting in non-continuous free surface reconstruction. In the localized Level-Set method, a continuous free surface is reconstructed, and thus the exact reflection points can be determined. The calculated spatial laser energy distribution and the corresponding molten pool dynamics from the two methods are analyzed and compared. The obtained numerical results are evaluated with experimental measurements to assure the validity of the proposed model. It is found that distinct patterns of the beam multiple reflections are obtained with the different free surface reconstructions, which shows significant influence not only on the molten pool behaviors but also on the localized keyhole dynamics.
This study presents mechanisms of the evolution of a narrowed region in the weld pool center during deep penetration laser beam welding. In numerous numerical studies presented in this study, it was also found that the local reduction of the weld pool size can cause detrimental effects on the melt flow behavior and the resulting properties of the welds. A particularly large influence of this effect was identified in three aspects. Firstly, the local variation of the solidification sequence of the weld pool causes an increase in the hot-cracking susceptibility due to a locally delayed solidification. Secondly, it was proven that a change in the local length and width of the weld pool is associated with an adverse impact on the potential flow routes of the molten material that induces stronger local variations of its solidification. Thus, the element mixing, e.g. during the welding with filler materials, is blocked. This leads to a non-homogeneous chemical composition of the final weld and can cause undesired effects on the final material properties. Finally, another observed effect is related to the reduced ability of process pores to reach the top surface. As this type of porosity is usually produced around the keyhole tip, the change of the fluid flow regime above this area plays a significant role in determining the final path of the pores until the premature solidification in the middle of the weld pool captures them. This study summarizes mainly numerical results which were supported by selected experimental validation results.
The Global Exploration Strategy of the International Space Exploration Coordination Group (ISECG) describes a timeframe of 2020 and beyond with the ultimate aim to establish a human presence on Mars towards the 2040ies. The next steps lie on the Moon with a focus on the coming 10 years. Early lunar surface missions will establish a capability in support of lunar science and prepare and test mission operations for subsequent human exploration of Mars and long-duration human activities on the Moon.
Given the extreme costs involved in the shipping of material from Earth, a prerequisite for future human exploration is the manufacturing of elements directly on the Moon’s surface. Unlike the equipment, which at the beginning will have to be brought from Earth, raw materials and energy could be available following the concept of In-Situ Resource Utilization. The ESA OSIP PAVING THE ROAD (PAVER) study investigates the use of a laser to sinter regolith into paving elements for use as roadways and launch pads thus mitigating dust issues for transport and exploration vehicles.
The ESA-funded study examines the potential of using a laser (12 kW CO2 laser with spot beam up to 100 mm) for layer sintering of lunar and martian regolith powders to manufacture larger 3D elements and provide know-how for the automatic manufacture of paving elements in the lunar environment. The project contributes to the first step toward the establishment of a lunar base and will lead to the construction of equipment capable of paving areas and manufacturing 3D structures.
PAVER project sets the starting point for an examination of the larger context of lunar exploration. Mission scenarios will look at different phases of lunar exploration: Robotic Lunar Exploration, Survivability, Sustainability, and Operational Phase. A proposed Technology Roadmap investigates the mission scenario and analyses how, and to which extent, laser melting/sintering will play a role in the various phases of exploration. The paper contextualizes laser sintering within selected mission scenarios and discusses the different kinds of infrastructure that can be produced at each phase of the mission. The outcome of the study includes the detailing of the TRL steps in the project and an outline of a timeline for the different elements. Covered aspects include terrain modelling such as operation pads, roadways, or towers, non-pressurized building structures to protect machinery, and habitat envelopes, to protect and shield humans against dust, micrometeoroids, and radiation.
In many cases, science falls back on self-developed prototype systems, which are used and developed for the measurement and execution of the tasks. About 80 % of the development is based on the same hardware design, which is used in only one application scenario and then discarded. For the most part, there are also uncalibrated sensors, since it is costly to calibrate a complicated sensor measurement system or the entire measurement chain since access to the sensor systems is not always available. This paper describes a conceptual design to implement a versatile sensor system with the motivation to fuse the data recording and data reception, which can cover large areas with the help of LoRaWAN (Long Range Wide Area Network) technology. To overcome disadvantages of LoRaWAN, namely the slow data rates, the proposed sensor system can also cover smaller areas with the widespread WiFi technology. An enormous advantage over individual complete systems in the form of a prototype, is the rapid expansion, uncomplicated calibration of the individual sensors and the ecological relief.
A modular design is used, where individual stacks with sensors and peripherals can be added separately. The stacks are standalone low-power systems and can be calibrated, maintained, and replaced separately and do not require the entire measurement chain. The measured and sent values are stored locally on the main stack and sent to the data collector (gateway) and evaluated by means of the automated selection between WiFi and LoRaWAN.
Simulating a Gas Source Localization Algorithm with Gas Dispersion Produced by Recorded Outdoor Wind
(2023)
This paper reports the use of the first gas dispersion simulator capable of introducing large wind fluctuations into simulations. The proposed simulator enables testing of a modification made to a gas source localization algorithm in a realistic scenario in order to study how the change affects it. Gas source localization in an outdoor environment is a challenging task mainly due to the complexity of the gas spread caused by the unpredictable nature of constantly changing wind. Therefore, a novel use of outdoor wind in developing a gas source localization system by simulation is presented in this paper. To consider the characteristic of sudden but large and unpredictable changes in wind direction, we propose to use recorded outdoor wind to simulate a realistic outdoor gas dispersion which has been done for the first time to the best of our knowledge. With the use of this simulator, we have tested a modification to a mobile robot-based gas source localization algorithm. Multiple simulations of the modified and the original particle filter-based algorithm have been done to study the effect of the tested modification. The results showed that a small difference in the algorithm can greatly impact the results. From this study, we show that the use of simulation consisting of the necessary traits to evaluate outdoor gas source localization, has the potential to accelerate the development of a reliable localization system.
To better understand the dynamics in hazardous environments, gas distribution mapping aims to map the gas concentration levels of a specified area precisely. Sampling is typically carried out in a spatially sparse manner, either with a mobile robot or a sensor network and concentration values between known data points have to be interpolated. In this paper, we investigate sequential deep learning models that are able to map the gas distribution based on a multiple time step input from a sensor network. We propose a novel hybrid convolutional LSTM - transpose convolutional structure that we train with synthetic gas distribution data. Our results show that learning the spatial and temporal correlation of gas plume patterns outperforms a non-sequential neural network model.
Earth buildings and adobe construction have been in use for thousands of years. Loam is locally available, environmentally friendly and has a small CO2 footprint mainly resulting from extraction and transport. Because of these reasons loam is one of the building materials of the future.
Water resistance is an important aspect when using loam as a construction material. If the structural option of building protruding roofs cannot be implemented, the water resistance of clay can be improved by stabilization.
Positive properties of the material should not be diminished by stabilization. For example, the desired regulation of air humidity, which however cannot be fully preserved by cement stabilization.
For an alternative and more appropriate stabilisation, different mixtures with calcined clays with alkali activator were examined. The calcination temperature for clays is usually lower than for cement and starts at 600° C. The calcined clays therefore also have a lower CO2 footprint compared to cement. To keep the mixture environmentally friendly potassium was used as alkali ion. It could be proven that the alkali activated polymer enhances water resistance of the loam mixture. Provided some further optimization the material shows potential to replace cement without compromising on the positive properties of clay.
The low calcination temperature for clays (600° C) and a low CO2 footprint compared to cement make them an interesting material. To find a stabilization method for loam using calcined clays, activation by alkalis was necessary. Therefore (and to keep the mixture environmentally friendly) KOH was used as alkali activator. It could be proven that the alkali activated polymer enhances water resistance of the loam mixture.
Diese Arbeit zeigt erstmals die Anwendung einer elektromagnetischen Schmelzbadsicherung beim einlagigen MSG-Schweißen von dickwandigen Stählen. Die innovativen Entwicklungen im Bereich des Lichtbogenschweißverfahrens ermöglichen eine Erhöhung der Abschmelzleistung, um die Einschweißtiefe zu steigern. Somit kann die Lagenanzahl reduziert und die Produktivität gesteigert werden. Allerdings besteht insbesondere beim einlagigen Schweißen von dickwandigen Bauteilen in PA-Position ein erhöhtes Risiko für das gravitationsbedingte Austropfen der Schmelze an der Wurzel. Zur Verhinderung werden Badsicherungen eingesetzt, die mechanisch angebracht und nach dem Schweißen entfernt werden müssen, was zeit- und kostenintensiv ist.
Die im Rahmen dieser Studie eingesetzte elektromagnetische Schmelzbadsicherung wirkt dem gravitationsbedingten Austropfen der Schmelze entgegen und kompensiert den hydrostatischen Druck. Sie wirkt kontaktlos, was im Gegensatz zu herkömmlichen Badsicherungen vorteilhaft ist, so dass auf eine zeit- und kostenintensive Nachbearbeitung der Schweißnahtwurzel verzichtet werden kann. Das auf extern angelegten oszillierenden Magnetfeldern beruhende Verfahren wird dabei unterhalb des zu schweißenden Bauteils positioniert. Die Magnetfeldlinien sind quer zur Schweißrichtung ausgerichtet, sodass längs zur Schweißrichtung Wirbelströme im Werkstück und eine stets nach oben gerichtete Lorentzkraft generiert werden. Mit Hilfe der elektromagnetischen Badsicherung konnten beim einlagigen MSG-Schweißen von bis zu 10 mm dicken Blechen die Tropfenbildung vermieden werden. Die innovative Technologie ermöglicht es, dickwandige Bauteile einlagig zu schweißen und reduziert die Nachbearbeitungszeiten und -kosten deutlich.
Die technischen Entwicklungen in der Lasertechnologie in den letzten Jahrzehnten haben eine neue Generation von Hochleistungslasersystemen im Leistungsbereich bis zu 100 kW auf den Markt gebracht. Dennoch ist die industrielle Anwendung des Hochleistungslaserstrahlschweißens auf bis zu 15 mm dicke Bleche beschränkt. Mögliche Ursachen der Einschränkungen des Verfahrens sind z.B. die Sensibilität des Verfahrens auf Fertigungstoleranzen wie Spalt und Kantenversatz, die erhöhte Tropfenbildung bei höheren Blechdicken und eine inhomogene Verteilung des Zusatzwerkstoffes beim Laserhybridschweißen. In dieser Studie wird ein auf extern angelegte Magnetfelder basierte elektromagnetische Schmelzbadstütze eingesetzt, um die Grenzen des Verfahrens zu erweitern und die Herausforderungen zu minimieren. Der wesentliche Vorteil der elektromagnetischen Schmelzbadstütze ist, dass sie berührungslos arbeitet. Mit Hilfe der elektromagnetischen Schmelzbadstütze konnten bei 20 mm dicken Proben aus S355J2 die Tropfenbildung an der Wurzel vermieden werden. Zudem wurde der Einfluss der Kantenqualität auf die Schweißnahtqualität untersucht, wobei verschiedene Schneidverfahren zur Kantenvorbereitung eingesetzt wurden, wie z.B. Plasma-, Brenn- oder Laserschneiden. Es konnte gezeigt werden, dass auch bei schlechteren Kantenvorbereitung im Gegensatz zu gefrästen Bauteilen die Werkstoffe einlagig mittels Laserhybridschweißen bei einer hohen Schweißnahtqualität gefügt werden konnten. Bei plasmageschnittenen Proben wurden zudem eine Spaltüberbrückbarkeit bzw. Kantenversatz von bis zu 2 mm sicher überbrückt. Des Weiteren war es mit Hilfe der externen Magnetfelder möglich, die Durchmischung des Zusatzwerkstoffes über die gesamte Schweißnahttiefe deutlich zu homogenisieren.
Turning maneuvers of rail vehicles involve demanding situations for the infrastructure because of the steering forces generated and the resultant lateral load transfers. Such forcing situation involves increased tangential forces that consume kinetic energy from the vehicle. While much attention has been paid in the literature to the damage in such infrastructure segments, the energy that is dissipated in these maneuvers, has not been explicitly addressed. In this paper, a specialized scale-down infrastructure is used to characterize the effect of the initial speed of the vehicle and its mass, on the magnitude of both the rail forces developed and the amount of dissipated energy during turning maneuvers. The outputs of the experiments suggest that most of the original kinetic energy is dissipated at the first portion of the turn. Also, that the magnitude of the wheel forces and the amount of dissipated energy, correlate. That is, a greater rail damage would correspond to greater energy dissipation.
When it comes to higher accuracies, new technologies and real applications in additive manufacturing, there is one topic which cannot be avoided: The material response on the chosen processing parameters and its agreement and correspondence with literature data of the wrought material grade counterpart. In industrial Additive Manufacturing (AM) standards in terms of printing parameters, protection gas atmospheres or powder handling instructions are not obligatory. Therefore, the question must be answered whether the AM process is reproducible and reliable over different printing companies. This was the motivation to realize a round robin test between 8 European printing companies and academic partners. The consortium had printed and tested fatigue and tensile testing bars under plant-specific conditions. A commonly used cast aluminum alloy, AlSi10Mg, was chosen as test material for the PBF-LB/M process. Differences of the results between the partners and the scatter itself were discussed in detail.
Microplastic detection in water samples becomes important for tracing microplastic sources. Microplastic may harm desalination facilities by blocking filters and disturbing the marine food chain. Thermo analytical methods such as pyrolysis gas chromatography mass spectroscopy, and spectroscopic methods like (micro) Raman spectroscopy or (micro) Fouriertransform infrared spectroscopy in combination with appropriate filters and sample preparation are suitable for analyzing microplastics on a scale from 1 µm to 1000 µm fast and unambiguous. While the thermo analytical methods are suitable for larger sample volumes, Raman spectroscopy and Fouriertransform infrared spectroscopy are able to detect and analyze single microplastic particles for instance in bottled water. Machine learning algorithms ensure a reliable classification of different plastic materials.
Der Fachbeirat kommt bereits seit 13 Jahren in seiner jetzigen Form zusammen, um Zulassungsrichtlinien, weitere Dokumente und fachliche Fragestellungen zu beraten. Die Zeit bringt auch personelle Veränderungen mit sich, darüber wollen wir berichten. Derzeit wird die Zulassungsrichtlinie für Schutzschichten im Fachbeirat und in seiner Arbeitsgruppe Geotextilien und Kunststoff Dränelemente (AG Geotextilien) überarbeitet. Zudem wurde die Zulassungsrichtlinie für Kunststoffdichtungsbahnen auf den aktuellen Stand der Regelsetzung und Normung gebracht. Bestimmte Medien, die hier bei einigen Prüfungen verwendet werden, dürfen nicht mehr in der EU in Verkehr gebracht werden. Hier werden die Hintergründe und Zusammenhänge in Kürze aufgezeigt. Zuletzt wird die Diskussion in Bezug auf den Einsatz von Rezyklaten in den zugelassenen Produkten aufgeführt.
Die vorliegende Untersuchung befasst sich mit dem Einfluss des Additive Manufacturing auf die Schweißeignung von Bauteilen aus Inconel 718. Hierfür wurden Proben mittels DED und L-PBF hergestellt und ihr Verhalten in Blindschweißversuchen anhand eines Vergleichs mit konventionellen Gussblechen untersucht. Im zweiten Schritt wurden die verschiedenen additiv hergestellten Proben mit dem Gussmaterial im I-Stoß sowie untereinander verschweißt.
Als Schweißverfahren wurde für alle Proben das Elektronenstrahlschweißen angewandt. Zur Auswertung wurde anhand von Schliffen das Nahtprofil vermessen und die Proben auf Poren und Risse untersucht. Zusätzlich wurde die Dichte vermessen und eine Prüfung auf Oberflächenrisse durchgeführt. Das AM-Material zeigte dabei Unterschiede in Nahtform und Defektneigung im Vergleich zum Gusswerkstoff. Insbesondere die DED-proben neigten unter bestimmten Parameterkonstellationen verstärkt zu Porenbildung. Risse konnten nicht beobachtet werden. Trotz auftretender Nahtunregelmäßigkeiten wurde in den kombinierten AM-Schweißproben die Bewertungsgruppe C erreicht. Eine Prüfung der bestehenden Regelwerke zur Schweißnahtbewertung anhand der gewonnenen Erkenntnisse zu additiv gefertigten Proben im Elektronenstrahlschweißprozess zeigte keinen Ergänzungsbedarf.
Für eine signifikante Festigkeitssteigerung von vergüteten, hochfesten Feinkornbaustählen mit einer Nominalstreckgrenze ≥ 690 MPa, ist die Zugabe von Mikrolegierungselementen, wie Nb und Ti, unerlässlich. Die Normvorgaben zur chemischen Zusammensetzung dieser Stähle (bspw. in DIN EN 10025-6) geben zur Erzielung der vorgeschriebenen Eigenschaften dabei oft nur Grenzgehalte für die Hersteller vor. Die Wirkung der Legierungselemente in der WEZ ist teilweise komplett konträr. Somit wird eine adäquate Vorhersage der Chargenabhängigkeit hinsichtlich der Schweißeignung und des Tragverhaltens der Schweißverbindung erschwert. Neben metallographischen Untersuchungen einzelner WEZ-Bereiche wurden unter Variation der chemischen Zusammensetzung, thermodynamische Phasenberechnungen mittels ThermoCalc durchgeführt. Hierdurch wird ein Verständnis zur Phasentransformation, Ausscheidungswachstum und -auflösung während des Schweißens in Abhängigkeit von Temperatur und Abkühlbedingungen geschaffen.
Der Weg zur digitalen Brücke ist eingeschlagen. Im Bereich der Planung, Bauüberwachung und -ausführung wird aktuell das Building Information Modelling (BIM) eingeführt. Ist eine Brücke in der Baulast von Bund und Ländern errichtet, wird ihr Zustand im Zuge von wiederkehrenden Bauwerksprüfungen nach DIN 1076 lückenlos überwacht. Abgespeichert werden die Informationen der Überwachung in einer Datenbank (ASB-ING Teilsystem Bauwerksdaten). Aus dieser Datenbank können anschließend relevante Informationen in ein objektspezifisches Bauwerksbuch überführt werden. In dieser Datenbank werden im Vorfeld definierte Daten abgespeichert. Reine Messdaten oder aber auch die verwendeten ingenieurtechnisch-physikalischen Modelle verbleiben in der Regel bei den beauftragen Dienstleistern. Zusammengefasst existieren verschiedene parallele Insellösungen der Informationsablage. Gegenstand verschiedener Forschungsanstrengungen ist es nun Lösungen zu finden, die einen ganzheitlichen Ansatz für den Informationsfluss von der Errichtung über den Betrieb bis hin zum Abbruch eines Bauwerkes sicherstellen. Im Rahmen einer prototypischen Entwicklung wird auf Grundlage, des für die Industrie 4.0 entwickelten open source Software Framework Eclipse BaSyx, ein möglicher Lösungsansatz – die Verwaltungsschale BBox (Bridge Box) - präsentiert. Dieser Lösungsansatz stellt das physikalisch-ingenieurtechnische Modell zur Zustandsbewertung der Brücke gedanklich in den Mittelpunkt. Unter der Voraussetzung einer durchgängigen Digitalisierung der gesamten Prozessschritte innerhalb der Lebensdauer der Brücke, kann jeder Planungs- und Fertigungsschritt, die Instandhaltung einschließlich des Rückbaus erfasst werden. Das Besondere hierbei ist, dass auch die Grundlagen der Bewertung, wie Messdaten, mit abgespeichert werden. Die Modellstruktur der Verwaltungsschale erlaubt hierbei eine bedarfsgerechte Granularität hinsichtlich der Messdaten auf allen virtuellen Ebenen, um das physikalisch-ingenieurtechnisch Modell mit Daten zu versorgen. Die gewählte Form der Datenablage bildet den Grundstein für zukünftige KI-Auswertungen z.B. mit den Methoden des Maschinellen Lernens (ML). Der Zugriff auf die dafür jeweils benötigten Daten wird durch die Ablage der Daten einschließlich Metadaten und den Einsatz einer Standard S3 Schnittstelle stark vereinfacht. Der Beitrag stellt die Entwicklung und die Systemarchitektur der BBox am Beispiel von 2 Projekten dar.
Der Kerbschlagbiegeversuch ist seit der ersten Hälfte des letzten Jahrhunderts standardisiert und seit langem als Prüfverfahren international genormt. Weltweit sind zu garantierende Werte der Kerbschlagenergie (KV) und Übergangstemperaturen (TÜ) in Produktnormen und Regelwerken festgelegt. Unter bestimmten Bedingungen besteht dabei die Option, statt Normalproben Untermaßproben zu prüfen. Im Rahmen einer Untersuchung der BAM wurde der aktuelle Status von Prüf- und Produktnormen sowie Regelwerken zur Bewertung der Bauteilintegrität hinsichtlich ihres Umgangs mit Untermaßprobenergebnissen erfasst. Zur Schaffung einer geeigneten aktuellen Datenbasis wurden an ISO-V-Proben der Dicken 2,5, 5,0, 7,5 und 10,0 mm aus vier aktuellen Baustählen KV2-T-Kurven ermittelt. Es wurden unterschiedliche Vorgehensweisen zur Kurvenanpassung und Festlegung von Übergangstemperaturen praktiziert. Ferner kamen verfügbare Ansätze zur Skalierung von Untermaßprobenergebnissen auf die Werte von Normalproben zur Anwendung. Das Ausmaß des Probendickeneffektes ist werkstoff- und temperaturabhängig. Im Bereich der Werkstoffprüfung ist akzeptiert, dass die Ergebnisse von Normal- und Untermaß-proben nicht ohne Weiteres ineinander überführt werden können. Der Stand der Produktnormung und der Regelwerke ist jedoch im besten Falle als unzureichend, vielfach jedoch schlicht als falsch zu bezeichnen. In einem weiten anwendungsrelevanten Temperaturbereich werden hier sogar deutlich nicht-konservative Skalierungsergebnisse geliefert. Die betroffenen Produkt-normenreihen und Regelwerke müssen überarbeitet werden.
Bei der Auslegung von Achsschenkeln für Nutzfahrzeuge wird für den Überlastfall ein fail-safe-Kriterium (kontrolliertes Versagen) als Basisphilosophie angesetzt. Gefordert wird, dass sich der Achsschenkel auch unter Akzeptanz begrenzten Risswachstums hinreichend elastisch-plastisch verformen kann, ohne dass es zum Bruch kommt. Der Fahrer soll anschließend anhand der bleibenden Verformungen bemerken können, dass mit seinem Fahrzeug etwas nicht in Ordnung ist. Eine Voraussetzung für dieses Bauteilverhalten ist eine hinreichende Bruchzähigkeit des Werkstoffs. Diese, wie auch die Rissspitzenbeanspruchung, müssen ermittelt werden, um den bruchmechanischen Sicherheitsnachweis führen zu können. Zur Ermittlung der mechanisch-technologischen und bruchmechanischen Werkstoffeigenschaften wurde ein Prüfkonzept entwickelt, bei dem die Proben an der potenziell kritischen Stelle direkt aus den geschmiedeten Achsschenkeln entnommen werden. Die experimentelle Werkstoffcharakterisierung bildet dann die Beanspruchungsbedingungen beim Überlastereignis ab. Im Rahmen der Produktion stehen jedoch nur Kerbschlagarbeitswerte zur Verfügung und aufwändige bruchmechanische Versuche sollen vermieden werden. Deshalb wurde eine Korrelation zur Abschätzung der vorhandenen Bruchzähigkeit aus der Kerbschlagarbeit herangezogen. Es ergibt sich eine Ergebnismatrix, die die Einflussgrößen Versagenswahrscheinlichkeit, Temperatur und Bruchzähigkeit verknüpft. Abschließend wird ein erster Vergleich der abgeschätzten mit den experimentell ermittelten Bruchzähigkeitswerten gezogen. Dieser weist aus, dass die abgeschätzten Werte geringfügig konservativ sind.
Für die Beförderung von umschlossenen radioaktiven Stoffen (Strahler) können Transporterleichterungen gelten, wenn das Strahlerdesign nachweislich unfallsicher ausgelegt ist und eine Zulassung als radioaktiver Stoff in besonderer Form vorliegt. Die in Deutschland zuständige Behörde für die Prüfung und Zulassung radioaktiver Stoffe in besonderer Form ist die Bundesanstalt für Materialforschung und –prüfung (BAM).
Eine oft langfristige Nutzung der Strahler kann eine alterungsbedingte Schwächung der Umschließung des radioaktiven Stoffes zur Folge haben. Jeder Strahler einer zugelassenen Bauart muss jedoch im Beförderungsfall zu jeder Zeit, auch nach längerer Nutzung, den vorgeschriebenen Prüfanforderungen genügen. Die Alterungsbewertung auf der Grundlage einer vom Antragsteller zu spezifizierenden Nutzungsdauer des radioaktiven Stoffes in besonderer Form ist seit langer Zeit Bestandteil des Zulassungsverfahrens in Deutschland. Ein von Deutschland eingebrachter Vorschlag im Rahmen der anstehenden Revision der IAEA Empfehlungen für die sichere Beförderung von radioaktiven Stoffen (SSR-6) soll die Lesbarkeit des Regelwerkes bezüglich der Alterungsbewertung verbessern, Klarheit über die damit verbundenen Anforderungen erzeugen und damit zu einer Harmonisierung der Zulassungsverfahren auf internationaler Ebene beitragen. In diesem Beitrag sollen wichtige Einflussfaktoren auf das Alterungsverhalten von radioaktiven Stoffen in besonderer Form aufgezeigt und die Notwendigkeit für die Spezifikation einer Nutzungsdauer als Grundlage für die Alterungsbewertung begründet werden. Der deutsche Vorschlag für die Revision des IAEA Regelwerks zum sicheren Transport radioaktiver Stoffe (SSR-6) wird vorgestellt und erläutert.
In line with the industrial trend of additive manufacturing, cold spray as a non-laser-based process is becoming increasingly important for many fields of application. For the evaluation of additive manufacturing of winding components made of copper for large electrical high-voltage machines, material and component properties such as electrical conductivity, mechanical load capacity and the component size that can be produced are of particular importance. In this context, the cold spray process offers advantages over laser-based additive manufacturing processes such as laser powder bed fusion (LPBF) or laser cladding by using the kinetic energy of the copper powder particles to generate particle cohesion. To investigate the electrical conductivity as well as the mechanical load capacity of cold spray parts, specimens were machined out of cold sprayed bulk copper deposits. The characteristic values were obtained with regard to the direction of deposition, which is defined by the direction of the robot’s movement. Thus, for the investigation of the component properties, specimens were provided that had been produced both longitudinally and transversely as well as orthogonally to the direction of deposition. The results of the investigations show that both the electrical conductivity and the mechanical load capacity of the specimen have a strong preferential direction of the specimen orientation with respect to the direction of deposition. Furthermore, it could be shown that by increasing the deposition height, there is an increasing oxygen content in the sample material, combined with increasingly significant defect networks. These effects have a negative impact on the electrical conductivity as well as on the mechanical load capacity. As a conclusion, further need for investigation is identified in the optimization of the process parameters as well as in the deposition strategy for the additive manufacturing of large-volume components with cold spray.
Corrosive geothermal brines are a major challenge to geothermal power-plants. For cost reasons, plant designers favorize low alloyed steels, e.g., carbon steel, which are susceptible to uniform and localized corrosion when exposed to geothermal brines having acidic and saline properties. To solve such problem, coatings or inhibitors would be a protective solution as an alternative to the use of high alloyed materials.
This study investigated a coating system consisting of polyaniline/silicon dioxide basing on locally available resources. Protection against corrosion of carbon steel is shown by long-term exposure and electrochemical tests of coated carbon steels, performed in an artificial acidic and saline geothermal brine, comparable to real conditions at a site in Indonesia.
Therefore, an integrated coating system is presented for corrosion protection, combining the electro-chemical functionality of polyaniline and the physical advantages of silica.
High-entropy alloys (HEAs) are innovative high-performance materials that have attracted more and more research attention. HEAs are characterized by a solid solution of typically five equiatomic metallic elements. In addition, medium-entropy alloys (MEA, with three elements) are of interest and become more and more important. Depending on the alloy concept, HEAs and MEAs show exceptional mechanical properties, especially high-strength and ductility combinations at both cryogenic and elevated temperatures combined with excellent corrosion resistance. Future structural HEA/MEA components can be exposed to potential applications with hydrogen containing environments like high-temperature water in pressurized nuclear reactors or aerospace structures. Other potential applications could be in materials for vessel walls in the field of cryogenic and high-pressure hydrogen storage. So far, the susceptibility of HEAs/MEAs to hydrogen assisted cracking (if any) and the hydrogen diffusion is not investigated in detail yet and can limit or extend possible applications of HEA/MEA as structural materials. In our work, we focused on the hydrogen absorption, diffusion, and distribution in a HEA (CoCrFeMnNi the original Cantor-alloy) and a MEA (CoCrNi). Cathodic hydrogen charging was carried out for the hydrogen ingress, and thermal desorption analysis (TDA) revealed complex hydrogen trapping in both alloy types up to 300 °C. The absorbed total hydrogen concentrations were > 100 ppm for the HEA and > 40 ppm for MEA. In addition, the assessment of the peak deconvolution is not trivial and must consider both experimental and microstructure influences.
Offshore wind turbines are an important goal in national energy strategies worldwide. Foundation structures are manufactured from submerged arc welded (SAW) plates with thicknesses up to 200 mm. In that connection, high-strength steels like the S420G2+M are more and more applied offering the possibility for increased stability and load-bearing capacity of the foundations. These offshore steel grades can show a susceptibility for delayed hydrogen assisted cold cracking of the weld joints. For that purpose, a minimum waiting time (MWT) of up to 48 h (dependent on applied standards) is recommended before non-destructive testing is allowed and conducted. But this concept is based on older steel grades that have been used for three or more decades. Nowadays, the metallurgical improvements (clean steels, proper rolling, and heat treatment) of base materials and well as welding consumables must be anticipated. Hence, the MWT concept should be critically discussed as it is assumed to be very conservative. For that reason, the focus of this study was to investigate the diffusion behavior in S420G2+M steel and its multi-layer SAW joint. Electrochemical permeation experiments were carried at room temperature. Boundary conditions were anticipated in terms of using different sample thicknesses. From the experimental data, hydrogen diffusion coefficients and absorbed diffusible hydrogen concentrations had been calculated. It was shown that hydrogen diffusion in the base material is increased compared to the weld metal. In addition, the sample thickness had a significant on the calculated diffusion coefficients. The minimum and maximum diffusion coefficients had been used for numerical modelling of the hydrogen diffusion in the welding joint. It became clear that a MWT must be always regarded together with a critical initial diffusible hydrogen concentration for the evaluation of a possible delayed cracking as diffusion times were mostly > 48 h due to the thick plates.
The majority of ultrasonic devices used for non-destructive testing in civil engineering require contact with the surface of the concrete (specimen), which significantly increases the time required for the measurement. This makes it impractical for extensive investigation of large-scale structures such as bridge decks, foundations, or tunnels.
In a pioneering approach, fluidic oscillators are used as contact free ultrasonic sources to overcome the aforementioned limitations. These robust and cost-effective actuators require only pressurised air and are ideally suited for harsh environments. At a constant supply pressure, they generate a continuous mono-frequent actuation signal. Further, varying the supply pressure via a fast pressure regulator was found to generate a frequency modulated signal which enabled time-of-flight measurement with an added advantage of increased signal to noise ratio. To demonstrate the feasibility of this novel idea of non-contact ultrasound, the results of the initial tests are presented.
Aschen und Schlacken und aus der Abfallverbrennung, chemische und mineralogische Zusammensetzung
(2022)
Aschen und Schlacken sind mengenmäßig der wichtigste Reststoffstrom in der thermischen Abfallbehandlung. Die enthaltenen elementaren Metalle werden mit gängigen Verfahren abgetrennt und einer Verwertung als Sekundärrohstoff zugeführt. Durch die chemische und mineralogische Zusammensetzung der mineralischen Fraktion wird das Umweltverhalten sowie die abfallrechtliche Einstufung bestimmt. Methoden zur Ermittlung der Einstufung werden vorgestellt. Das Löslichkeitsverhalten von Schwermetallen in gealterten Aschen hängt meist vom pH-Wert in den standardisierten Auslaugtests ab. Das davon abweichende Verhalten von Antimon wird detailliert beschrieben.
Laser welding is an appropriate technique for joining Laser Powder Bed Fusion (L-PBF) parts together and to conventional wrought ones. The potential consists of profiting from synergies between additive and conventional manufacturing methods and overcoming the existing limitations of both. On the one hand, L-PBF is a widely spread metal-based additive manufacturing technique suitable for generating complex parts which can present intrinsic designed cavities, conformal cooling channels, and filigree structures contributing to sustainable manufacturing and efficiency-oriented designs. On the other hand, chamber sizes for producing L-PBF parts are limited, and the process is time-consuming. Thus, its employment is not for every geometry justified. Additionally, they are in most cases individual elements of a larger assembly and need to be joined together to conventionally fabricated parts.
The present research suggests laser welding parameters to adequately bond pairs of wrought and L-PBF processed plates and two L-PBF plates of Inconel 718 in butt position. L-PBF samples are printed in three different build-up orientations. Additionally, the influence of as-built L-PBF roughness qualities and usual pre-weld preparations such as edge milling are examined. The effect of normed pre-weld heat treatments is also contemplated. Identified cracks are analyzed by means of EDS in order to confirm the present phases on the areas of interest. EBSD is also employed to obtain a clear depiction of the crystallographic texture and distribution of the hot cracks.
The quality of the weldment was examined according to existing standards. Substantial differences in seam geometry and microstructure across different edge’s surface qualities and build directions of stress relieved L-PBF parts have not been detected. Nevertheless, even if no other irregularities are present in the seam, variability in liquation cracking susceptibility has been confirmed. This defect is prone to happen when parts made of this nickel-based superalloy are welded together when not enough precautions are taken. It has been determined that grain size and ductility of the material before welding play a crucial role and mitigating or intensifying these imperfections. Moreover, recommendations are presented to avoid this potential welding defect.
Laser Induced Breakdown Spectroscopy – A Tool for Imaging the Chemical Composition of Concrete
(2022)
One of the most common causes of damage is the ingress of harmful ions into the concrete, which can lead to deterioration processes and affect structural performance. Therefore, the increasingly aging infrastructure is regularly inspected to assess durability. Regular chemical analysis can be useful to determine the extent and evolution of ion ingress and to intervene in a timely manner. This could prove more economical than extensive repairs for major damage, particularly for critical infrastructure. In addition to already established elemental analysis techniques in civil engineering such as potentiometric titration or X-ray fluorescence analysis, laser-induced breakdown spectroscopy (LIBS) can provide further important complementary information and benefits. The possibilities of LIBS are demonstrated using the example of a drill core taken from a parking garage.
In this paper, a cost-efficient distributed fiber optic measurement system based on Rayleigh scattering is presented. The distributed digital incoherent optical frequency domain reflectometry (I-OFDR) method is developed for detection of significantly large strain in the range from 3 % up to 10 % as required by end users. For this purpose, a vector network analyzer used in the I-OFDR is replaced by a compact and cost-effective digital data acquisition system. This digital emitting/receiving unit enables the recording of the complex transfer function carrying information about the local deformations along the entire sensing fiber.
Untersuchung zur Herstellung von Cu-Strukturen mittels Wire Electron Beam Additive Manufacturing
(2022)
Das Additive Manufacturing gewinnt zunehmend an Bedeutung für die Fertigung metallischer Bauteile im industriellen Umfeld. Hierbei wird zunehmend auch auf drahtförmige Ausgangswerkstoffe gesetzt, da diese Vorteile im Handling bieten, bereits in der Industrie etabliert sind und sich in der Regel durch geringere Beschaffungskosten auszeichnen. In den letzten Jahren entwickelte sich neben den bereits im großen Umfeld untersuchten Wire-DED-Verfahren auch eine Prozessvariante unter Nutzung des Elektronenstrahls zur industriellen Marktreife. Dabei zeigt die als Wire Electron Beam Additive Manufacturing bezeichnete Technologie besondere Vorteile gegenüber anderen, zumeist Laser- oder Lichtbogen-basierten DED-Prozessen. Das Verfahren bietet vor allem Potenzial für die Verarbeitung von hochleitfähigen, reflektierenden oder oxidationsgefährdeten Werkstoffen. Insbesondere für die Herstellung von Bauteilen aus Kupferlegierungen zeigt sich der Elektronenstrahl als besonders geeignet. Um das Verfahren einem breiten Anwenderkreis in der Industrie zugänglich zu machen, fehlen jedoch übergreifende Daten zu Leistungsfähigkeit, Prozessgrenzen und Anwendungsmöglichkeiten. Die vorliegende Untersuchung beschäftigt sich mit dieser Problemstellung am Beispiel zweier Cu-Werkstoffe. Dabei werden ein korrosionsbeständiger Werkstoff aus dem maritimen Bereich sowie eine Bronze mit guten Verschleißeigenschaften aus dem Anlagenbau getestet.
Über mehrstufige Testschweißungen wurden die physikalisch möglichen Prozessgrenzen ermittelt und Rückschlüsse über die Eignung der Parameter zum additiven Aufbau gezogen. Hierfür wurden zunächst optimale Bereiche für den Energieeintrag anhand von Volumenenergie sowie mögliche Schweißgeschwindigkeiten untersucht.
Anschließend wurde die Skalierbarkeit des Prozesses anhand von Strahlstrom und Drahtvorschub getestet.
Als wesentliche Zielgrößen wurden dabei Spurgeometrie, Aufmischung und Härte herangezogen. Die Eignung der ermittelten Parameter wurde im letzten Schritt exemplarisch anhand einer additiven Testgeometrie in Form eines Zylinders nachgewiesen.
Safety and reliability are the major challenges to face for the development and acceptance of hydrogen technology. It is therefore crucial to study deeply material compatibility, in particular polymer materials that are directly in contact with hydrogen. This paper presents an experimental study on the fretting wear behavior of two types of cross-linked hydrogenated acrylonitrile butadiene rubbers against 316L steel ball in hydrogen environment. Furthermore, aging experiments were conducted for 7 days under static conditions in 100 MPa hydrogen. the influences of hydrogen pressure as well as the aging exposure on the fretting behavior are discussed by means of surface analyses along with the material properties.
Holz wird vielfach in Stoßdämpfern von Transportbehältern für radioaktives Material eingesetzt. Dafür wird oftmals Fichtenholz verwendet, das in mehreren Lagen und senkrecht zueinander liegender Faserrichtung zwischen einer inneren und einer äußeren Stahlhülle eingebaut wird. Die Reibung zwischen den dabei entstehenden Grenzflächen ist von entscheidender Bedeutung für die Stoß- und Energieabsorption, z. B. bei einem Aufprall des Behälters auf eine harte Unterlage. Um detaillierte Informationen für entsprechende numerische Simulationen zu bekommen, wurden in dieser Arbeit die Reibungszahlen von Holz-Holz- und Holz-Stahl-Paarungen bei für derartige Behälter relevanten Beanspruchungsbedingungen im Temperaturbereich zwischen -40°C und 90°C gemessen. Die Ergebnisse zeigen eine gleichmäßige, mit steigender Temperatur abfallende Reibung, wobei die Werte für Holz-Stahl-Paarungen zwischen 0,43 bei -40°C und 0,22 bei 90°C sowie für Holz-Holz-Kontakte zwischen 0,3 bei -40°C und 0,24 bei 90°C liegen.
Investigating the spalling behaviour of a concrete mixture using large scale members is complex and expensive. Thus, the susceptibility of concrete to spalling is investigated by means of fire tests on small scale specimens. However, the reduction of the fire exposed surface increases the influence of boundary effects. Macrocracking and the water loss via the lateral surfaces reduce the impact of the thermomechanical and thermohydraulic damage mechanisms and therefore, lower the risk of spalling. Thus, the influence of different restraints on the spalling behaviour of intermediate scaled specimens (Ø=0.47 m; h=0.29 m) was investigated for two ordinary concrete mixtures. Both mixtures had the same composition except the type of aggregate. One mixture contained only quartzitic aggregates, whereas the other mixture was made with basalt grit as coarse aggregates. Applied steel rings restrained the thermal expansion of the specimen and prevented the loss of water, whereas applied steel sheet primarily reduced the loss of water during the fire test. Additionally, the fire exposed surface of one specimen of each mixture was pre-dried under controlled climate conditions and fire tested with applied steel rings. The results show a higher spalling volume for the ring restrained specimens compared to the other covering types. Further, the pre-dried boundary zone leads to delayed and decreased occurrence of spalling compared to the non-dried specimens for the concrete with quartzitic aggregates and to a prevention of spalling for the mixture with basalt aggregates. Additionally, the results show that the influence of the thermomechanical behaviour of the coarse aggregates increases with increasing restraint. The restrained conditions of the specimens with applied steel ring are comparable to the conditions in the centre of a large scale member. This test series is a further step for possible concept of steel ring restraint concrete specimens as “screening-tests” in upcoming projects.
The attenuation of wave amplitudes is ruled by the planar, cylindrical or spherical geometry of the wave front (the geometric or power-law attenuation) but also by the damping of the soil (an exponential attenuation). Several low- and high-frequency filter effects are derived for the layering and the damping of the soil, for the moving static and the distributed train loads and for a homogeneous or randomly heterogeneous soil. Measurements of hammer- and train-induced vibrations at five sites have been analysed for these attenuation and filter effects. The measured attenuation with distance can be discribed by generalised power laws and some reasons will be discussed. The theoretical filter effects can well be found in the measurements.
Druckbehälter mit großen Wandstärken (250+ mm) aus hochwarmfesten, niedriglegierten Stählen werden hauptsächlich Mehrdraht-Unterpulver-(UP) geschweißt. Der damit verbundene hohe Energieeintrag führt unter anderem zu hohen lokalen Schweißeigenspannungen, welche bei unsachgemäßer Prozessführung der notwendigen Wärmenachbehandlung (PWHT) zu Spannungsrelaxationsrissen (SRR) führen. In den Bewertungskriterien zur Spannungsrelaxationsrissanfälligkeit finden weder die, mit klassischen, freischrumpfenden Schweißversuchen nicht abbildbaren, erhöhten Eigenspannungen aus der Schrumpfbehinderung der Bauteilsteifigkeit Beachtung, noch die damit einhergehenden metallurgischen Effekte wie bspw. das Ausscheidungswachstum während der PWHT und damit einhergehende Härteunterschiede an den Korngrenzen bzw. die vorzeitige Alterung durch Bildung differenter Sonderkarbide. Die Aufheizrate des PWHT als Einflussfaktor für die SRR-Bildung bleibt derzeit ebenfalls unbeachtet.
Daher wurde eine Versuchsmethodik entwickelt, die eine mögliche SRR-Anfälligkeit durch die Kopplung von thermischer und mechanischer Beanspruchung untersucht. Dazu wurden Proben mit unterschiedlichen Gefügen thermisch simuliert und während des PHWT repräsentativ mit sehr hohen Lasten/Eigenspannungen mechanisch beansprucht.
Dazu wurde an Kleinzugproben für das as-welded UP-Schweißgut und die thermisch simulierte GKZ eines 13CrMoV9-10 die Dehnung des Prüfbereichs bei variablen Querspannungen und Aufheizraten gemessen. Diese aufheizraten- und gefügeabhängige Längenänderung der Probe wurde durch mathematische Prozeduren analysiert. Damit war es möglich, singuläre werkstoffliche Effekte auf μm-Ebene (Ausscheidungswachstum) als summarische Längen- bzw. Volumenänderung per klassischer Kurvendiskussion zu beschreiben. Die erste und zweite Ableitung zeigten eine ausscheidungsabhängige Härtezunahme, welche von der Spannung und Aufheizrate im geringen Maß linear abhängig war. Gleichzeitig sind Volumenänderungen bei Bildung und Wachstum differenter Sonderkarbide bekannt, welche zusammen mit gefügespezifischen Untersuchungen und der neuen Versuchsmethodik zu einer verbesserten Beurteilung der SRR-Anfälligkeit von geschweißten CrMoV-Stählen beitragen sollen. Prinzipiell ist die vorgestellte Methodik jedoch werkstoff- und zustandsoffen, d.h. sowohl für Grundwerkstoff e als auch definierte Wärmebehandlungsbedingungen geeignet. Dies ermöglicht erstmals die Schaffung einer Transfergröße zwischen Labor und realen Schweißungen, unter Beibehaltung der Bauteilsteifigkeit, d.h. vereinfachte, aber realistische Eigenspannungsabbildung als Grundlage für weitergehende gefügespezifische metallurgische Effekte während des PWHT.
Komponenten aus dickwandigen, hochwarmfesten CrMoV-Stählen erfordern eine anspruchsvolle UP-Schweißverarbeitung. Dabei muss die notwendige Wärmenachbehandlung der Schweißnaht (PWHT) sicher beherrscht werden.
Hier kann u.U. Bauteilversagen infolge von Spannungsrelaxationsrissbildung (SRR) auftreten. Bislang erfolgt die Beurteilung der SRR-Neigung primär über Ersatzgrößen, wie temperaturbedingte Änderung der Härte und Duktilität.
Die Wirkung der konstruktiven Schrumpfbehinderung einer Schweißnaht auf die SRR ist bislang völlig unbekannt.
Hier setzt das Forschungsprojekt an, hinsichtlich der Gewinnung und Optimierung der Parameter für die PWHT unter realitätsnahen Bauteilsteif igkeiten (def inierte Einspannbedingung) mit dem Ziel der SRR-Vermeidung. Am Beispiel des niedriglegierten, hochwarmfesten Stahls 13CrMoV9-10 wurden UP- Schweißungen unter industriepraktischen Bedingungen freischrumpfend bzw. unter definierter Schrumpfbehinderung durchgeführt. Diese wurden mit unterschiedlichen PWHT-Szenarien (Variation der Auf heizrate und Endtemperatur) beaufschlagt. Die Ergebnisse des Projektes DVS 01.2261 / IGF 20171 N werden in diesem Beitrag vorgestellt, wie Aussagen zur SRR-Suszeptibilität in Abhängigkeit von Mikrostruktur und vorliegender mehrachsiger mechanischer Beanspruchung der Schweißnaht vor/während des PWHT. Für einen kritischen Zustand sind hohe Kräfte / Spannungen notwendig, die in freischrumpfenden Schweißversuchen u.U. nicht abbildbar sind. Die Berücksichtigung des mikrostrukturspezifischen Ausscheidungsverhaltens (in Schweißgut und Wärmeeinflusszone) unter realitätsnahen Einspannbedingungen ist für die Bewertung einer SRR-Suszeptibilität notwendig. Instrumentierte Schweißversuche unter definierter Schrumpfbehinderung ermöglichen hier das Monitoring der entstehenden Reaktionskräfte, -momente bzw. -spannungen. Ausgehend von diesem Referenzzustand erfolgte die Applikation der PWHT-Szenarien bzw. deren praktische Überprüfung. Zusätzlich wurde eine Ersatzprüfmethodik entwickelt, die die Betrachtung der mikrostrukturspezifischen SRR-Suszeptibilität unter Beibehaltung der äußeren Schrumpfbehinderung der Schweißnaht während des PWHT ermöglicht. Hierdurch wird die Bauteilübertragbarkeit ermöglicht und eine Transfergröße geschaffen, welche die Bauteilbewertung hinsichtlich der SRR-Neigung umfasst.
Remote sensing of hazardous substances is a key task that can be achieved with the help of remotely operated platforms equipped with specific sensors. A huge variety of methods and used vehicles have been developed for different purposes in recent years. The term smart dust refers to a science fiction novel and develop shortly after into a research proposal at UC Berkley funded by DARPA. Subsequently, the topic gained attraction but was overall considered as to complex for the technologies available at that time. In the launched passive smart dust project, we shift to a simple “chemical intelligent” passive sensor particle on the ground combined a read-out active sensor attached to an Unmanned Aerial Vehicle (UAV). The reactive particle surface can be preadjusted in the lab for exact desired properties regarding certain reactions to hazardous substances.
Moreover, the aimed interaction with the active sensor can be modified. Planed applications allow for different materials e.g., for short time measurement, being ecologically degradable, or weather stable for long time monitoring.
Occupational health is an important topic, especially in industry, where workers are exposed to airborne by-products (e.g., dust particles and gases). Therefore, continuous monitoring of the air quality in industrial environments is crucial to meet safety standards. For practical and economic reasons, high-quality, costly measurements are currently only carried out sparsely, both in time and space, i.e., measurement data are collected in single day campaigns at selected locations only.
The project “Robot-assisted Environmental Monitoring for Air Quality Assessment in Industrial Scenarios” (RASEM) addresses this issue by bringing together the benefits of both – low- and high-cost – measuring technologies enabling costefficient long-term air quality monitoring in realtime: A stationary network of low-cost sensors that is augmented by mobile units carrying high-quality sensors. By mapping the distribution of gases and particles in industrial environments with the proposed RASEM system, measures can be identified to improve on-site working conditions much faster than using traditional methods.
In this paper, we detail the technical aspects of RASEM and introduce the mobile platforms used.
The Sharp GP2Y1010AU0F is a widely used low-cost dust sensor, but despite its popularity, the manufacturer provides little information on the sensor. We installed 16 sensing nodes with Sharp dust sensors in a hot rolling mill of a steel factory. Our analysis shows a clear correlation between sensor drift and accumulated production of the steel factory. An eye should be kept on the long-term drift of the sensors to prevent early saturation. Two of 16 sensors experienced full saturation, each after around eight and ten months of operation.
Aero-engine turbine disks are safety-relevant components which are operated under high thermal and mechanical stress conditions. The actual part qualification and certification procedures make use of spin-tests conducted on productionsimilar disks. While these tests provide, on the one hand, a reliable definition of the critical conditions for real components, on the other hand they represent a relevant cost item for engine manufacturers. The aim of this work is to present part of a fracture mechanics-based procedure under development which aims at replacing the tests on production-similar disks with lab tests on fracture mechanics specimens. In particular, the rimpeeling failure mode is considered as case study. A semi-circular surface crack is modelled at the most stressed region at the diaphragm of a turbine disk, with the crack plane perpendicular to the radial direction. The crack is therefore subjected to a biaxial stress state and grows under increasing rotational speed until it triggers the rim-peeling failure. The finite element simulation of the cracked disk considers the real thermal and mechanical loading conditions. In order to design a lab representative specimen, beside the crack driving force, expressed in terms of -integral, also the constraint to plastic deformation e.g., stress triaxiality, at the crack-tip must be similar for the same crack in the specimen and in the disk. This has been achieved and as expected, both the highest -integral and constraint factor are calculated at the same location along the crack front for both disk and specimen. The results of the structural integrity assessment in the form of a Failure Assessment Diagram (FAD) show good agreement between designed specimen and disk both in terms of expected failure mode and value of the critical speed. Probabilistic aspects are also considered in the calculations.
One of the main advantages of additive manufacturing (AM) processes such as laser powder bed fusion (PBF-LB/M) is the possibility to manufacture complex near-net-shape components. Therefore, the PBF-LB/M process is becoming increasingly important for the manufacturing and repair of gas turbine blades. Despite the great freedom in design, there are also limitations to the process. Manufacturing overhangs or bridging voids are some of the main challenges. In the conventional PBF-LB/M process, overhangs with angles up to 45° can be manufactured. However, gas turbine blades feature voids for cooling, which have to be bridged when using PBF-LB/M. In this work, different concepts for bridging voids are developed for future application in gas turbine blade repair. For this purpose, a test geometry is derived from the tip area of a gas turbine blade as a reference. By changing the initial geometry of the reference body, different designs for bridging voids are developed based on the PBF-LB/M requirements. Subsequently, these distinct designs are manufactured by PBF-LB/M. The different approaches are compared with respect to their volume increase. In addition, the specimens are visually inspected for warpage, shrinkage and imperfections by overheating. Out of the seven concepts developed, three concepts can be recommended for gas turbine blade repair based on low volume increase, distortion and shrinkage.
European tribological research organisations unify their capabilities for the European Tribology Centre (https://www.i-tribomat.eu/). At its core is a database, which data are made comparable and trusted via harmonised procedures for their generation. This contribution will focus on wear volume data.
A Memorandum of Understanding (MOU) between Argonne National Laboratory (Argonne) and the German Bundesanstalt für Materialforschung und -prüfung (BAM) was signed in October 2014. Its objectives are to promote cooperation among scientists and specialists at Argonne and BAM and establish a framework for collaboration in advanced technologies associated with the back end of the nuclear fuel cycle. Collaborative activities involving Argonne and BAM may be implemented through the promotion of joint research activities and scientific workshops and conferences; exchange of technical information; and visits by scientists, specialists, and graduate, postgraduate, and Ph.D. students. The MOU was renewed in January 2020 for another five years. Highlights of the progress and achievements are provided in identified topical areas for collaboration on ageing management guidance, storage, transportation and disposal R&D, joint conference activities, and conclude with the benefits of the MOU in fostering Argonne and BAM collaboration.
Für eine signifikante Festigkeitssteigerung von vergüteten, hochfesten Feinkornbaustählen mit einer Normstreckgrenze > 690 MPa, ist die Zugabe von Mikrolegierungselementen, wie Nb und Ti, unerlässlich. Die Normvorgaben zur chemischen Zusammensetzung dieser Stähle (bspw. in DIN EN 10025-6) geben zur Erzielung der vorgeschriebenen Eigenschaften dabei oft nur Grenzgehalte für die Hersteller vor. Die Wirkung der Legierungselemente bzw. ihrer Karbide und/oder Nitride ist teilweise komplett konträr, insbesondere bei Auflösung und Wiederausscheidung in der WEZ bei identischem Schweißzusatz. Somit wird eine adäquate Vorhersage der Chargenabhängigkeit hinsichtlich der Schweißeignung und des Tragverhaltens der Schweißverbindung erschwert. Zuzüglich können moderne Schweißprozesse, wie MSG mit modifiziertem Sprühlichtbogen (mod. SLB) durch ihre hohe Wärmeeinwirkung die Phasenumwandlung in der Wärmeeinflusszone negativ beeinflussen. Eine unerwünschte Eigenschaft ist dabei die Erweichung (engl.: softening) der WEZ, wie auch u.U. der gegenteilige Effekt der Aufhärtung (engl.: hardening). Vor diesem Hintergrund werden im Rahmen eines DFG-Vorhabens systematisch Mikrolegierungsrouten mit variierenden Ti- und Nb-Gehalten des hochfesten und vergüteten Feinkornbaustahls S690QL untersucht. Dazu wird das MAGSchweißen mit mod. SLB verwendet, welches durch hohe Abschmelzleistung gekennzeichnet ist und schmalere Fugenöffnungswinkel (α = 30°) ermöglicht. An diesen Schweißungen wird der Effekt der metallurgischen Zusammensetzung in Kombination mit hoher Wärmeeinwirkung auf die Ausbildung einer kritischen WEZ-Gefügezone mit Erweichung und/oder exzessiver Aufhärtung untersucht. Ein besonderes Augenmerk wird auf die Phasenumwandlungen und das Ausscheidungsverhalten im Gefüge der Wärmeeinflusszone gelegt. Neben umfangreichen metallographischen Untersuchungen einzelner WEZ-Bereiche wurden, unter Variation der chemischen Zusammensetzung, thermodynamische Phasenberechnungen mittels ThermoCalc durchgeführt. Hierdurch wird ein Verständnis zur Phasentransformation und Ausscheidungswachstum und -auflösung während des Schweißens in Abhängigkeit von Temperatur und Abkühlbedingungen geschaffen. Das Ziel ist es, mittels erster Untersuchungen den Einfluss der Wärmeeinwirkung auf die Gefügeausbildung in der WEZ zu zeigen. Insbesondere wird hier auf die Auswirkung der unterschiedlichen Mikrolegierungskonzepte (Ti oder Nb) geachtet.
Underground sealing structures are necessary to seal radioactive or toxic waste in underground repositories. A special version of MgO concrete is used in the mine in Teutschenthal and applied at a large-scale test with the aim to provide a low permeability barrier. The test structures (up to 10 m long) were created by shotcreting. Besides destructive tests, non-destructive ultrasonic measurements have been evaluated for quality assurance to monitor potential anomalies such as cracks, concrete inhomogeneities, and delamination. We show results of ultrasonic measurements with a multi-transducer system used at the front and from the side of the concrete structure. Images are obtained by synthetic aperture focusing techniques. The boundaries between concreting sections are not visible in the ultrasonic images systematically so that a successful concreting is assumed, which is confirmed by the low permeabilities observed. Several reflectors up to a depth of 1.2 m are identified and interpreted as potential damages in the concrete. Phase analysis of prominent reflectors reveal a negative impedance contrast thus indicating air filled voids, cracks or delamination. Boreholes through some of the identified reflectors are used to verify the results from ultrasonic measurements. Additionally, an experiment with incorporated artificial defects was undertaken to analyse the reliability of the applied methods. Overall, the conducted tests show the potential of ultrasonic measurements to detect critical anomalies. Despite challenges at small-scale structures (cm-order), large-scale anomalies can be identified. Consequently, implementing ultrasonic monitoring during and after the construction of concrete sealing structures has shown its potential as a tool for quality assurance, but needs further development and validation.
Thermal spraying enables a fast and propelling way to additively deposit various ceramics as electric insulators, which are used in conditions where polymers are not suitable. Alumina (Al2O3) is among the most employed materials in the coating industry since it exhibits good dielectric properties, high hardness, high melting point while still being cost-effective. Various parameters (e.g. feedstock type, plasma gas mixture, plasma power) significantly influence the resulting coating in terms of microstructure, porosity, crystallinity, and degree of un-or molten particles. As a consequence, these parameters need to be investigated to estimate the impact on the electrical insulating properties of thermally sprayed alumina. This study focuses on the development of a novel electric insulation coating from Al2O3 feedstock powders deposited via atmospheric plasma spray (APS). The microstructure, porosity, and corresponding crystallographic phases have been analyzed with optical microscopy, XRD, and SEM images. To achieve an understanding of the parameters influencing the electrical insulation performance of the manufactured coatings, an in-depth analysis of the fundamental dielectric parameters e.g., DC resistance, breakdown strength, dielectric loss tangent, permittivity is presented.
Der diesjährige Beitrag zeigt den Einfluss ausgewählter Versuchsrandbedingungen auf das Abplatzverhalten von Normalbeton im kleinskaligen Brandversuch. Im Rahmen der Untersuchungen wurde die Abplatzneigung von acht zylindrischen Betonprüfkörpern der Maße Ø47 cm x 29 cm aus Normalbeton analysiert. Vier Prüfkörper wurden aus Normalbeton mit quarzitischer Gesteinskörnung hergestellt, wohingegen die grobe Gesteinskörnung (>2 mm) der anderen vier Prüfkörper durch Basaltsplitt ersetzt wurde. Neben der Art der groben Gesteinskörnung wurden zusätzlich ausgewählte Versuchsrandbedingungen variiert. Dies umfasste zum einen die Vorlagerung der Prüfkörper bei verschiedenen Umgebungsfeuchten und zum anderen die Ummantelung der Prüfkörper mit zwei Ringen aus Stahl bzw. einem durchgehenden Stahlblech. Die Ummantelung der Prüfkörper mit Stahlringen im Brandversuch führt zu einer Behinderung der thermischen Ausdehnung der Prüfkörper und zum Aufbau thermomechanischer Zwangsdruckspannungen. Diese Zwangsdruckspannungen werden maßgeblich von der thermischen Ausdehnung der verwendeten Gesteinskörnung beeinflusst. Zusätzlich wird die Feuchteabgabe über die Mantelfläche behindert. Der Einsatz des Stahlblechs reduziert lediglich die Abgabe der Feuchtigkeit über die Mantelfläche und induziert vernachlässigbare Zwangsdruckspannungen im Beton. Die Brandbeanspruchung der Prüfkörper erfolgte einseitig nach der Einheits-Temperaturzeitkurve (ETK) über einen Zeitraum von 60 Minuten. Mit Hilfe eines Laser Scanners wurden vergleichende 3D-Messungen der brandbeanspruchten Oberfläche vor und nach dem Brandversuch durchgeführt. Aus diesen Messungen konnten das Abplatzvolumen, die Abplatztiefenverteilung und die maximale Abplatztiefe ermittelt werden. Während des Brandversuchs wurde die Temperaturverteilung im Prüfkörper mittels fünf eingebetteter Mantelthermoelemente in verschiedenen Tiefen bestimmt. Die Ergebnisse zeigen, dass die Abplatzungen an der brandbeanspruchten Oberfläche infolge der Prüfkörperummantelung mit Stahlringen bzw. Stahlblech zunehmen. Bei einer Ummantelung mit Stahlringen mit gleichzeitiger Vortrocknung der Betonrandzone platzt der Prüfkörper mit quarzitischer Gesteinskörnung ab, wohingegen der Prüfkörper mit basaltischer Gesteinskörnung keine Abplatzungen aufweist. Dies wird auf die unterschiedliche Ausprägung der thermomechanischen Schädigung infolge der unterschiedlichen thermischen Ausdehnungskoeffizienten von Quarzkies und Basalt zurückgeführt.
Die Ergebnisse der Brandprüfserie zeigen, dass die Variation der Prüfrandbedingungen bei Beibehaltung der Prüfkörpergröße einen maßgeblichen Einfluss auf das Abplatzverhalten haben. Die Randbedingungen sind daher bei kleinskaligen Brandversuchen, die zukünftig als „Screening-Tests“ ersatzweise für kostenintensive Bauteilversuche verwendet werden sollen, zu berücksichtigen.
Der Beitrag stellt experimentelle Untersuchungen zum Feuerwiderstand von Carbonzuggliedern vor. Die Anwendung von Zuggliedern aus Carbon ist durch die außergewöhnlich gute Ermüdungs- sowie hohe Zugfestigkeit des Werkstoffs motiviert. Ferner ergibt sich gegenüber Stahl eine deutliche Reduzierung des Querschnitts. Perspektivisch sollen damit Stahlzugglieder im Netzwerkbogenbrückenbau ersetzt werden. Durch die Materialsubstitution werden Ressourcen nicht nur beim Zugglied selbst, sondern auch am Gesamttragwerk der Brücke eingespart. Da zum Tragverhalten von Carbonzuggliedern im Brandfall bislang keine Erkenntnisse vorliegen, sollen mit Hilfe von Bauteilbrandversuchen die Versagensmechanismen sowie die grundsätzliche Gleichwertigkeit gegenüber konventionellen Stahlhängern untersucht werden.
Der Beitrag beschreibt die Durchführung und die Ergebnisse von Brandversuchen an mechanisch belasteten Carbonzuggliedern. Die realmaßstäblichen Versuche werden am unikalen Zugbauteil-prüfofen der BAM im Mai 2022 durchgeführt. Das Versuchsprogramm umfasst vier Carbonzugglieder mit kreisrunden Querschnitten in zwei verschiedenen Durchmessern, ⌀36 mm und ⌀51 mm. Aus Gründen der Vergleichbarkeit erfolgt die Brandbeanspruchung nach Einheits-Temperaturzeitkurve (ETK). Während des Brandversuches wird die axiale Prüfkraft von 750 kN bzw. 1500 kN bis zum Eintreten des Probenversagens konstant gehalten. Zusätzlich werden die Längsverformung sowie die Bauteil- und Brandraumtemperaturen aufgezeichnet.
In einem Vorversuch an einem unbelasteten Bauteilabschnitt eines Carbonzuggliedes konnte das Brand- und Erwärmungsverhalten des Verbundmaterials untersucht werden. Dabei zeigten sich Makrorisse und eine Zersetzung der Kunststoffmatrix sowie eine hohe Temperaturbeständigkeit der Kohlenstofffasern. Durch das Fehlen der schützenden Matrix reagierten die Carbonfasern sensibel auf Querbeanspruchung. Dies führte zu einem Bruch und Ablösen der oberflächennahen Fasern.
Intumescent coatings are used in civil engineering to improve the fire resistance of steel constructions. Due to the thin coating thickness and the profile-following application, the architectural appearance of the steel structure can be preserved. EN 13381-8 provides regulations to determine the contribution to the fire resistance of intumescent coatings applied to steel beams and columns. The scope of this standard excludes tension members and steel members with solid sections. For products that have already been successfully tested and assessed on beams and columns, EN 13381-10 offers the possibility based on unloaded fire tests to extend the scope of application of intumescent coatings to tension bars with solid sections. This approach contradicts the national safety level in Germany, where mechanically loaded testing is mandatory. Therefore, a new part of the test standard series EN 13381 is currently developed to enable the application of intumescent coatings on steel tension bars with solid section based on mechanically loaded fire tests. BAM has already carried out numerous fire tests on loaded steel tension members with intumescent coatings. Currently, in the BAM research project FIRESTEMIC, the influence of the steel bar orientation and the profile type on the thermal performance of intumescent coatings are investigated. Both questions concerning the thermal protection ability of intumescent coatings were analysed based on three different test sets, which were carried out in the tension furnace (Fig. 1a). The fire exposure corresponds to the standard temperature-time curve according to EN 1363-1.
This paper summarises the main findings from the fire tests conducted in the FIRESTEMIC project. The results serve as an experimental background for the proposal of the new standard. Regarding the bar orientation, a new test setup was developed and proposed for the new standard. The two tested commercial water-based intumescent coatings with applied dry film thickness from 1.5 mm to 2.5 mm showed only a slight dependence on the bar orientation. In terms of the steel profile type, circular and rectangular solid sections with identical section factor and applied dry film thickness were tested. It was observed that the circular solid bars with diameter 30 mm heat up faster compared to the solid rectangular bars with dimension 30×30 mm (Fig. 1b). Also at larger steel bars, i.e. diameter 40 mm and dimension 40×40 mm, the same trend occurred. Thus, it is recommended for the new test standard to allow a transfer of the test results from circular to rectangular solid sections. In addition, the paper will describe and explain the test and assessment procedure proposed for the newly developed standard.
Bei einer turnusmäßigen Inspektion der B1 Brücke am Altstädter Bahnhof in Brandenburg an der Havel wurden im Dezember 2019 Risse und Hohlstellen entlang der Längsträger festgestellt. Als Ursache wurde das Versagen eines signifikanten Anteils der Spanndrähte der konzentrierten Spannglieder vermutet. Die Brücke wurde umgehend für den Verkehr gesperrt und nach weiteren, umfassenden Untersuchungen im Mai 2021 abgebrochen.
Um die Sicherheit des unter der Brücke geführten Verkehrs zu gewährleisten, wurde die Brücke unter anderem mit einem Schallemissionsmesssystem überwacht. Mit diesem Verfahren ist es möglich, Spanndrahtbrüche zuverlässig zu detektieren und zu lokalisieren. In dem gut einjährigen Überwachungszeitraum wurden mehr als einhundert Spanndrahtbrüche detektiert, die in einigen Bereichen der Brücke besonders konzentriert auftraten.
Vor dem Abbruch der Brücke war es möglich, den Nachweis der Detektion von Spanndrahtbrüchen mit der Schallemissionsanalyse und ihre Ortungsgenauigkeit anhand von künstlich erzeugten Drahtbrüchen zu validieren. Weiterhin konnte das sichtbare Schadensbild, Längsrisse und Hohlstellen über den Spannkanälen, auf die lokale Schädigung der Spanndrähte zurückgeführt werden. Derzeit wird ein Merkblatt erarbeitet, in dem die Erfahrungen in der bisherigen Anwendung der Schallemissionsanalyse zum Monitoring von Spanndrahtbrüchen zusammengefasst werden.
In diesem Beitrag werden die Grundlagen der Schallemissionsanalyse und die Ergebnisse der Validierungsversuche an der Brücke in Brandenburg dargestellt. Weiterhin werden die Vorteile und Grenzen der Brückenüberwachung mittels Schallemissionsanalyse sowie Maßnahmen zur Sicherstellung der Qualität und der Zuverlässigkeit diskutiert.
Monte-Carlo-Analysis of Minimum Burst Requirements for Composite Cylinders for Hydrogen Service
(2021)
For achieving Net Zero-aims hydrogen is an indispensable component, probably the main component. For the usage of hydrogen, a wide acceptance is necessary, which requires trust in hydrogen based on absence of major incidents resulting from a high safety level. Burst tests stand for a type of testing that is used in every test standard and regulation as one of the key issues for ensuring safety in use. The central role of burst and proof test is grown to historical reasons for steam engines and steel vessels but - with respect for composite pressure vessels (CPVs) - not due an extraordinary depth of outcomes. Its importance results from the relatively simple test process with relatively low costs and gets its importance by running of the different test variations in parallel. In relevant test und production standards (as e. g. ECE R134) the burst test is used in at least 4 different meanings. There is the burst test on a) new CPVs and some others b) for determining the residual strength subsequent to various simulations of ageing effects. Both are performed during the approval process on a pre-series. Then there is c) the batch testing during the CPVs production and finally d) the 100% proof testing, which means to stop the burst test at a certain pressure level. These different aspects of burst tests are analysed and compared with respect to its importance for the resulting safety of the populations of CPVs in service based on experienced test results and Monte-Carlo simulations. As main criterial for this the expected failure rate in a probabilistic meaning is used. This finally ends up with recommendations for relevant RC&S especially with respect to GTR 13.
The oxidation of sulfur in aqueous solutions is an important process in several geochemical and industrial contexts. In concrete technology, it is particularly relevant for the protection of steel reinforcement in slag cement-based concretes, as the presence of sulfides affects the passivation of the steel and corrosion initiation in the presence of chlorides. However, the knowledge about the kinetics of sulfide oxidation in alkaline solutions, such as concrete pore solutions, is incomplete. To address this issue, we prepared solutions with 0.80 M NaOH, and nominally 10, 100 and 350 mM HS−, respectively, and followed the evolution of the sulfur species during bubbling with oxygen-containing gas (concentration 100% or 22%) using X-ray absorption near-edge structure (XANES) spectroscopy at the sulfur K-edge. Polysulfide, thiosulfate, sulfite and sulfate were identified and quantified via linear combination fitting of the spectra, using previously measured standards. A preliminary analysis of the results shows that the initial rate constant of sulfide oxidation depends strongly on the HS− concentration, while it less strongly depending on the oxygen concentration, in line with previous results for lower pH values. Approaches to fit the data to obtain the rate constants of all relevant reactions will be discussed.
Brückenbauwerke, die im Spannblockverfahren hergestellt wurden, können bauartbedingt wasserstoffinduzierte Spannungsrisse über den gesamten Querschnitt eines Spannkanals aufweisen. Das Risswachstum kann infolge dynamischer Beanspruchung über die Nutzungsdauer fortschreiten und zu Spanndrahtbrüchen führen.
This study aims to develop a real time structural health monitoring method by ultrasonic tests combined with advanced six component (6C) translation and rotation measurements. Conventionally, the investigation of the velocity and acceleration response in the translation direction is used to obtain the eigenfrequencies of structures. Recently the measurement of rotation has been considered to fully characterize the dynamic behavior of structures. This research undertakes the evaluation of a novel 6C sensor (IMU50-iXblue) with components originally developed for navigation for the purpose of bridge monitoring. However, as for all vibration recordings, there is a certain influence of environmental conditions (mainly temperature) which may affect evaluation and the results of structural assessment. We propose applying the cross-correlation function to the 6C ambient vibration signals to reconstruct wave propagation and using coda wave interferometry (CWI) to obtain internal velocity variation from waveforms. A field experiment on a large-scale prestressed concrete bridge model is presented. To verify that we are able to identify the pre-stress loss even in presence of temperature effects, we perform measurements in two different scales: the ultrasonic and output-only, vibration measurements. The change in the structural properties due to the pre-stress loss should be detected by the pulse velocity change. The results reveal both the performance and advantages of ultrasonic techniques and the capabilities of 6C sensors. To conclude, the application of CWI to wave signals contributes to a comprehensive assessment for bridge monitoring.
Support structures of wind turbines in German offshore wind farms are regularly inspected. Currently, inspection outcomes are generally not systematically recorded. This prevents their consistent handling and processing, which is a key requirement to enable an efficient structural integrity management. As part of the DiMoWind-Inspect project, a data model and reference designation system for such inspection results is developed to facilitate their identification, localization, quantification, tracing and linking throughout the lifetime of a wind farm and beyond. The inspection results together with structural health monitoring results and information on repairs form the basis for assessing and predicting the structural condition, estimating the remaining lifetime, and planning of future inspections, structural health monitoring, and repairs. As a basis for developing a digital structural integrity management, a generic framework is proposed in this paper, which describes the stakeholders, data, models, processes and workflows of the integrity management of support structures in offshore wind farms and their interrelations. The framework adopts a building information modelling approach to describe the information relevant to the structural integrity management. The central digital space of the framework is a common data environment. An implementation of the framework will enable a digital structural integrity management in which inspection, structural health monitoring, repair, assessment and planning outcomes generated throughout the life cycle of a wind farm can be consistently collected, managed, shared and processed by the relevant shareholders.
Die B1 Brücke am Altstädter Bahnhof in Brandenburg an der Havel wurde im Dezember 2019 aufgrund von während einer turnusmäßigen Inspektion entdeckten Rissen und Hohlstellen entlang der vorgespannten Längsträger gesperrt und im Mai 2021 abgebrochen. In der Zwischenzeit wurde die Brücke detailliert überwacht. Vor dem Abriss wurden zudem umfangreiche Untersuchungen zur Bestandsaufnahme und Schadensanalyse sowie Tests moderner Sensorik vorgenommen. Dabei konnte sowohl die richtige, zuvor nicht sicher bekannte Anzahl von Spanngliedern in den Querträgern sicher ermittelt werden als auch durch moderne Varianten der Schwingungsmessungen und der faseroptischen Sensorik zusätzliche Kenntnisse püber das Bauwerksverhalten ermittelt werden . In dem Beitrag werden die Verfahren mit ihren Möglichkeiten und Grenzen vorgestellt, die Ergebnissee an der Brücke in Brandenburg erläutert und zukünftige Einsatzmöglichkeiten diskutiert.
This contribution introduces an investigation of a large-scale prestressed concrete bridge model (“BLEIB” structure at the BAM-TTS open air test site) by means of on-site cooperative measurements. This bridge has an external post-tensioning system and has been instrumented with the ultrasonic transducers, temperature sensors and optical fibers for Distributed Acoustic Sensing (DAS). Our experiment was designed to test the suitability of the novel 6C sensors developed within the framework of the GIOTTO project – the IMU50. The IMU50 sensor enables vibration measurements in translation along three axes and rotation around three axes. The geophone sensors were considered for complementary measurements of vertical velocity response. In the experiment, several perturbations were achieved by controlling the external influence factors such as loading and prestressing changes. The aim of the integrated measurement strategy was to fully observe the results of the condition change and to verify the effectiveness of multiple sensors for bridge monitoring.
To reveal the corrosion resistance of casing steel/mortar interface in CO2 injection condition, sandwich samples were prepared and exposed up to 20 weeks in aquifer fluid under 10 MPa and 60 °C. Cross section analysis revealed the crevice corrosion as main mechanism instead of pitting corrosion, which would be expected to happen in the extremely high Chloride concentration. Detailed analysis using EDS line scan shown the slow diffusion of Chloride, suggesting why pitting did not happen after 20 weeks. To mimic the passivated steel surface, the steel coupon was passivated in simulated pore solution having pH 13.5 for 42 days. The passivated coupon was further exposed to NGB solution for 28 days. Electrochemical characterization was performed along the exposure processes to reveal the change in impedance, indicating the corrosion resistance of steel casing/mortar interface.
Environmental protection, resource conservation and CO2 reduction require new joining concepts for effective multi-material design in automotive lightweight construction. The thermal joining of dissimilar materials, especially the combination of aluminum alloys and steel, is associated with difficulties. Different material properties, such as melting point and coefficient of thermal expansion, complicate joining processes. Furthermore, the insolubility between these materials results in the formation of intermetallic phases. These brittle phases reduce the load-bearing capacity and quality of the joints. The thickness of the intermetallic phases should not reach the critical value of 10 μm to ensure good mechanical properties of the joint. It is known that a two-phase reaction layer consisting of Al5Fe2 and Al3Fe (also known as Al13Fe4) forms at the interface between solid steel and liquid aluminum. Due to high cooling rates, as it is the case in laser beam welding, metastable intermetallic compounds can form different from the equilibrium state. The formation of the intermetallic reaction layer is a diffusion-controlled process. So, it is only possible to control the growth of these phases. This problem has led to use joining methods that do not require the melting of both joining partners. A promising joining method is laser beam welding-brazing, whereby only one joining partner is melted and wets the solid joining partner. Conventional laser beam welding-brazing only results in material-fit joints and often requires the use of expensive filler materials. An additional form-fit could optimize the mechanical performance of the joint. For this reason, a new joining method for overlap configurations of dissimilar materials was developed. A laser beam melts the lower joining partner through a cavity of the upper joining partner. The created melt pool is moved upwards into the cavity of the upper joining partner due to contactless induced Lorentz forces of an AC-magnetic system. The displaced melt creates a form- and material-fit joint after solidification. The advantage of this joining technology is the absence of filler materials, flux agents and expensive auxiliary joining elements.
With increasing focus on industrialized processing, investigating, understanding, and modelling the structural build-up of cementitious materials becomes more important. The structural build-up governs the key property of fresh printable materials -- buildability -- and it influences the mechanical properties after the deposition. The structural build-up rate can be adjusted by optimization of the mixture composition and the use of concrete admixtures. Additionally, it is known, that the environmental conditions, i.e. humidity and temperature have a significant impact on the kinetic of cement hydration and the resulting hardened properties, such as shrinkage, cracking resistance etc. In this study, small amplitude oscillatory shear (SAOS) tests are applied to examine the structural build-up rate of cement paste subject to different temperatures under controlled humidity. The results indicate significant influences of the ambient temperature on the intensity of the re-flocculation (Rthix) rate, while the structuration rate (Athix) is almost not affected. A bi-linear thixotropy model extended by temperature dependent parameters coupled with a linear viscoelastic material model is proposed to simulate the mechanical behaviour considering the structural build-up during the SAOS test
Scaled-down experimental facility: Can reproduce actual failures; can produce simulated data for identifying cracks in the substructure or other defects. The acceleration data can be converted into an equivalent deformation. The experimental facility can analyse dynamic loads. Equivalent force data: Facilitates the application to a health monitoring system; simplifies the development of predictive maintenance. These data is helpful in validating analytical or simulation models.
Damage Assessment of Civil Structures Using Wave Propagation Analysis and Transmissibility Functions
(2022)
A common damage detection method in civil engineering is to monitor dynamic characteristics such as natural frequencies and modal shapes, which are directly related to the structural stiffness. However, the discrepancy in measured natural frequencies may result from environmental changes, the soil-structure interaction or effects caused by earthquakes. This makes it difficult to decide whether the local change in structural properties is caused by damage or other factors. To address this challenge and thus improve the current damage detection method, the wave propagation analysis method and the transmissibility relationship were considered. In our study, the wave propagation field in structures was reconstructed by applying the Normalized-Input-Output-Minimization (NIOM) method to vibration recordings. Wave velocities and transmissibility functions were considered as reference values for the damage indicators. This paper demonstrates the evaluation of local property changes in two examples of large-scale structures: a 14-story RC building and a 64 m long pedestrian bridge. The proposed damage indicators show a clear correspondence to structural changes.
Closed material cycles and unmixed material fractions are required to achieve high recovery and recycling rates in the building industry. The growing diversity of construction and demolition waste is leading to increasing difficulties in separating the individual materials. Manual sorting involves many risks and dangers for the executing staff and is merely based on obvious, visually detectable differences for separation. An automated, sensor-based sorting of these building materials could complement or replace this practice to improve processing speed, recycling rates, sorting quality, and prevailing health conditions.
A joint project of partners from industry and research institutions approaches this task by investigating and testing the combination of laser-induced breakdown spectroscopy (LIBS) and visual (VIS)/ near-infrared (NIR) spectroscopy. Joint processing of information (data fusion) is expected to significantly improve the sorting quality of various materials like concrete, main masonry building materials, organic components, etc., and may enable the detection and separation of impurities such as SO3-containing building materials (gypsum, aerated concrete, etc.). Focusing on Berlin as an example, the entire value chain will be analyzed to minimize economic/technological barriers and obstacles at the cluster level and to sustainably increase recovery and recycling rates.
First LIBS measurements show promising results in distinguishing various material types. A meaningful validation shall be achieved with further practical samples. Future works will investigate the combination of LIBS and VIS/NIR spectroscopy in a fully automated measurement setup with conveyor belt speeds of 3 m/s.
In a joint project of partners from industry and research, the automated recycling of construction and demolition waste (CDW) is investigated and tested by combing laser-induced breakdown spectroscopy (LIBS) and near-infrared (NIR) spectroscopy. Joint processing of information (data fusion) is expected to significantly improve the sorting quality of various materials like concrete, main masonry building materials, organic components, etc., and may enable the detection and separation of impurities such as SO3-cotaining building materials (gypsum, aerated concrete, etc.). The project focuses primarily on the Berlin site to analyze the entire value chain, minimize economic/technological barriers and obstacles at the cluster level, and sustainably increase recovery and recycling rates. First measurements with LIBS and NIR spectroscopy show promising results in distinguishing various material types and indicate the potential for a successful combination. In addition, X-ray fluorescence (XRF) spectroscopy is being performed to obtain more information about the quantitative elemental composition of the different building materials. Future work will apply the developed sorting methodology in a fully automated measurement setup with CDW on a conveyor belt.
The global COVID-19 pandemic has brought far-reaching changes for our society. Suddenly, millions of people spent the majority of their time at home - either due to a lock down or by switching from office to working remotely. This paper offers a literature review regarding pandemic-related behavioural changes and a first mapping of likely consequences for EU Ecodesign regulations. These impacts are considered for product groups that are already regulated by EU Ecodesign or are under discussion for future regulation. Furthermore, potential for smart home applications are analysed exemplarily. We identified which behavioural changes have the potential to become established in the long-term. This might need to result in adaptions for regulations under the Ecodesign Directive and EU-Energy Labelling regulations to better reflect the recently appeared usage profiles. It might require different priority settings regarding the product groups to be regulated and communicated to users, due to online shopping proliferation, to be updated. Changed behaviour can be observed in product groups such as ICT, consumer electronics and household appliances. Examples include the increased use of laptops and tablets for digital teaching, use of gaming devices and office equipment in private households (IT, printing and network devices) and changed cooking behaviour. This resulted in increased sales of some product types. Online sales became even more important than in-store sales, which also means that consumers are increasingly informed online about energy efficiency. More do-it-yourself (DIY) home projects result in more frequent - not yet regulated - DIY power tool use and over the long run might stimulate the need for (semi-)professional tools. The changes in behaviour patterns also offer the opportunity to optimize consumption by means of smart homes and smart products. However, the control of networked household appliances requires additional energy for standby states and data exchange. As an illustrative example, we discuss the conflict between higher energy consumption for smart system components and the possible optimization of consumption in private households.
Funktional gradierte Materialien auf Basis von Stellite und Stahl im Laserpulver-Auftragschweißen
(2022)
Das Hinzufügen von Stellite auf Stahl ist eine typische Vorgehensweise um Bauteile gegen Verschleiß und Korrosion zu schützen. Der Sprung in den Materialeigenschaften kann jedoch zu Rissen und somit zum Versagen der Beschichtung führen. Um die Lebensdauer von Beschichtungen zu erhöhen wird daher ein gradierter Übergang mit verschiedenen Materialpaarungen untersucht.
Interdigital transducers (IDTs) are a well-known tool for excitation of surface acoustic waves. The use of IDTs is versatile, but they are most commonly employed as actuators for excitation of ultrasonic guided waves (UGWs). However, they are still a relatively new technology, which leaves many possibilities for future research, especially in the scope of newly emerging structural health monitoring (SHM) systems. IDTs offer low weight, design flexibility and beam directivity, which make them ideal candidates for employment in such systems.
Due to the IDTs’ and waves’ complexity, problems often cannot be described analytically, therefore they require numerical solutions and experimental validations. In this contribution, a novel, simple use of IDTs, in the scope of SHM is described. Firstly, numerical findings acquired with finite element method are presented. To validate those results, experiments in a plate-like waveguide are carried out. A good agreement between them is found. The results show the potential of the IDTs in yet another prospective application, which could be attractive for adoption in the future.
Structural health monitoring (SHM) intends to improve the management of engineering structures. The number of successful SHM projects – especially SHM research projects – is ever growing, yielding added value and more scientific insight into the management of infrastructure asset. With the advent of the data age, the value of accessible data becomes increasingly evident. In SHM, many new data-centric methods are currently being developed at a high pace. A consequent application of research data management (RDM) concepts in SHM projects enables a systematic management of raw and processed data, and thus facilitates the development and application of artificial intelligence (AI) and machine learning (ML) methods to the SHM data. In this contribution, a case study based on an institutional RDM framework is presented. Data and metadata from monitoring the structural health of the Maintalbrücke Gemünden for a period of 16 months are managed with the RDM system BAM Data Store, which makes use of the openBIS data management software. An ML procedure is used to classify the data. Feature engineering, feature training and resulting data are performed and modelled in the RDM system.
Die Thermografie beruht auf der bildlichen Darstellung von Temperaturunterschieden oder auch thermischen Kontrasten an der Oberfläche eines Untersuchungsobjektes. Diese bilden sich nur her-aus, wenn sich das Untersuchungsobjekt gerade erwärmt oder abkühlt. Der Beitrag erklärt mittels eines stark vereinfachten Modells die Entstehung solcher Kontraste als dynamischen Effekt verschiedener Abkühlgeschwindigkeiten. Neben Laborergebnissen werden beispielhaft einige Ergeb-nisse von einem mittelalterlichen Baudenkmal präsentiert, um das Verständnis für die thermografische Inspektion von Fassaden zu vertiefen.
The contribution discusses the processing and analysis of data generated on two different ways of investigations for impact damage in reinforced concrete structures. Damage investigations are essential to determine type and characteristics of damage and thus the residual capacity. Damage describing data is generated using two different types of investigation, a non-destructive tomographic as well as numerical examination. Subsequently, data of both sources was merged and analysed. Within the research project “Behaviour of structural components during impact load conditions caused by aircraft fuel tank collision” reinforces concrete plates were damaged by impact loading, see Hering (2020). Afterwards the damaged specimens were investigated tomographically as well as numerically using several methods and models. Aim of the presented research work was to specify an objective comparability of numerical data with experimentally determined damage patterns and based on this, to establish a quantitative damage evaluation.
Falltürme sind Bauwerke, die als Versuchsanlagen sehr speziellen, impulsartigen Belastungen ausgesetzt sind. Am Fallturm auf dem Testgelände Technische Sicherheit (TTS) der BAM wurde bei Routineinspektionen eine Abnahme der strukturellen Integrität in Form von Vorspannungsverlusten in den Bolzen der Stahlverbindungen festgestellt. Um ein Verständnis für die zugrundeliegenden Trag- und Schädigungsmechanismen zu erlangen, wurde ein umfassendes Structural Health Monitoring (SHM) System geplant und am Bauwerk installiert unter Nutzung von digitalen Bauwerksmodellen. Für die Auslegung des Überwachungssystems, insbesondere aber zur Unterstützung der Untersuchung des Schädigungsprozesses, wurden Finite-Elemente-Modelle erstellt. Um sicherzustellen, dass die FE-Modelle das reale Tragwerksverhalten mit ausreichender Genauigkeit abbilden, mussten sie jedoch in Bezug auf die gemessenen Antworten des Tragwerks kalibriert werden. Der vorliegende Beitrag beschreibt experimentelle und numerische Untersuchungen zur Identifizierung des strukturellen Systems des Stahlrohrgitterturms in Vorbereitung einer Überwachungskampagne. Die Auswertung von gemessenen Schwingungen unter ambienter Anregung ermöglichte die Identifizierung der Eigenfrequenzen mehrerer globaler Schwingungsmoden des Fallturms. Zur Modellvalidierung wurde zunächst eine Sensitivitätsanalyse durchgeführt, um die Parameter mit dem größten Einfluss zu ermitteln. Anschließend wurde ein evolutionärer Algorithmus (EA) zur Optimierung nach dem Prinzip der Minimierung der Differenzen zwischen gemessenen und simulierten charakteristischen Antworten eingesetzt. Das aktualisierte Modell wurde schließlich an der dynamischen Reaktion der Turmstruktur infolge einer realen Falltest-induzierten Stoßbelastung validiert. Die Ergebnisse zeigten eine gute Übereinstimmung zwischen numerischen und experimentellen Ergebnissen.
A digital structural integrity management of offshore structures enables an optimized planning of inspections and repairs with risk-based methods. In a risk-based approach, the inspection and repair strategy that minimizes the expected lifetime costs consisting of the expected inspection, repair and failure costs is determined. In addition to inspections, information on the structural condition can be continuously obtained by monitoring the vibration response of the structural system. Changes in the vibration characteristics quantified in terms of modal properties can be an indication of structural damage. In risk-based inspection and repair planning, the effect of monitoring results is determined via Bayesian updating of the structural condition and reliability. This information should be applied to inform decisions on inspections and may result in a reduced inspection effort. The benefit of continuously monitoring the structural health can be quantified in terms of the value of information, which corresponds to the difference between the expected lifetime costs with and without monitoring. In this work, we demonstrate in a numerical example how an optimized sensor placement for a vibration-based structural health monitoring system can be determined by maximizing the value of information.
The general aim of this research is the development of methods for predicting mechanical behavior and identification of limiting conditions to prevent brittle failure of high-burnup (HBU) pressure water reactor (PWR) fuel cladding alloys. A finite element (FE) model of the ring compression test (RCT) was created to analyze the failure behavior of zirconium-based alloys with radial hydrides during the RCT. An elastic-plastic material model describes the zirconium alloy. The stress-strain curve needed for the elastic-plastic material model was derived by inverse finite element analyses. Cohesive zone modeling is used to reproduce sudden load drops during RCT loading. Based on the failure mechanism in non-irradiated ZIRLO® claddings, a micro-mechanical model was developed that distinguishes between brittle failure along hydrides and ductile failure of the zirconium matrix. Two different cohesive laws representing these types of failure are present in the same cohesive interface. The key differences between these constitutive laws are the cohesive strength, the stress at which damage initiates, and the cohesive energy, which is the damage energy dissipated by the cohesive zone. Statistically generated matrix-hydride distributions were mapped onto the cohesive elements and simulations with focus on the first load drop were performed. Computational results are in good agreement with the RCT results conducted on high-burnup M5® samples. It could be shown that crack initiation and propagation strongly depend on the specific configuration of hydrides and matrix material in the fracture area.
Ni alloys are generally classified as difficult-to-cut materials and cost intensive. Additive manufacturing (AM) offers economic advantages. However, machining of these AM components is mandatory to create the final contour or surface. The inhomogeneous and anisotropic microstructure and properties of AM components causes an unstable cutting process. Moreover, undesirable tensile residual stresses are generated due to subsequent machining. In this investigation, the initial alloy 36 is modified with Ti and Nb up to 1.6 wt.-% and build-up welded via gas metal arc welding (GMAW) and plasma-transferred-arc (PTA). Then, finish-milling tests are carried out to investigate the influence of the modification as well as the cutting parameters on the resulting cutting force and the surface integrity. In addition, the conventional milling process (CM) is compared with the ultrasonic-assisted milling process (US), which has a significant influence on the machinability as well as on the surface integrity.
The decommissioning or refurbishment of nuclear facilities necessitates either the storage or disposal of large radioactive components such as steam generators, pressurizers, reactor pressure vessels and heads, and coolant pumps, to list the major contributors. These components or objects are large in size and mass, measuring up to approximately 6 meters in diameter, up to 20 meters in length, and weighing over 400 000 kg. In many situations, the components are transported off-site to a storage, disposal or recycling/treatment facility. Previously, many large objects had to be transported under special arrangement.
The latest 2018 edition of the International Atomic Energy Agency (IAEA) Regulations for the Safe Transport of Radioactive Material, No. SSR-6 [1], incorporates regulations for the shipment of large objects as a new category of surface contaminated object, SCO-III, based on the IAEA “performance package” concept. This paper provides background and practical guidance on these regulations.
Additionally, the experiences of BAM with the appoval of two steam converters of the NPP Lingen are presented as the first approval process for SCO-III objects in Germany.
The primary additions to SSR-6 include SCO-III classification and requirements, approval and administrative requirements for the new classification, and the addition of SCO-III to the proper shipping
name for UN 2913. Advisory material drafted for the new requirements will be included in the next revision of SSG-26, Advisory Material for the IAEA Regulations for the Safe Transport of Radioactive Material, expected to be published soon.
Note that at this time the proposed provisions for large objects do not include components such as reactor vessels, due to the more limited experience and greater radioactivity levels. The SCO-III concept lays the groundwork and may be extended to cover other large objects that are classified as low specific activity (LSA) material in the future.