Wissenschaftliche Artikel der BAM
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Degradation of AISI 630 exposed to CO2-saturated saline aquifer at ambient pressure and 100 bar
(2018)
In general high alloyed steels are suitable as pipe steels for carbon capture and storage technology (CCS), because they provide sufficient resistance against the corrosive environment of CO2-saturated saline aquifer which serves as potential CCS-site in Germany. High alloyed martensitic steel AISI 630 has been proven to be sufficient resistant in corrosive environments, e.g. regarding heat, pressure, salinity of the aquifer, CO2-partial pressure), but reveals a distinct corrosion pattern in CCS environment. Therefore coupons of AISI 630 heat treated using usual protocols were kept at T=60 °C and ambient pressure as well as p=100 bar up to 8000 h in an a) water saturated supercritical CO2 and b) CO2-saturated synthetic aquifer environment similar to on-shore CCS-sites in the Northern German Basin. AISI 630 precipitates a discontinuous ellipsoidal corrosion layer after being exposed for more than 4000 hours. Best corrosion resistance in the CO2-saturated synthetic aquifer environment phase is achieved via normalizing prior to exposure. In water saturated supercritical CO2 tempering at medium temperatures after hardening gives lowest corrosion rates. Corrosion fatigue via push-pull tests with a series of 30 specimens was evaluated at stress amplitudes between 150 MPa and 500 MPa (sinusoidal dynamic test loads, R=-1; resonant frequency ~ 30 Hz). The endurance limit of AISI 630 is reduced by more than 50% when exposed to CCS environment (maximum number of cycles (10 x 106) at a stress amplitude of 150 MPa).
A shell test bench was developed at BAM 5.3 which allows for static and fatigue testing of curved fiber-reinforced plastic (FRP) structures, during which in-situ the damage state can be non-destructively inspected by thermography and strain-field measurement techniques. Sandwich shell specimens with typical wind turbine blade manufacturing defects were designed and tested. The tested imperfections show a fairly significant reduction (up to 90%) of the shell test specimens‘ lifetime, depending on the type of imperfection. Using the in-situ NDT methods incorporated in the shell test bench, the location and cycle time of the initial defects and the damage evolution was investigated.
Due to rapid, localized heating and cooling, distortions accumulate in additive manufactured laser metal deposition (LMD) components, leading to a loss of dimensional accuracy or even cracking. Numerical welding simulations allow the prediction of these deviations and their optimization before conducting experiments. To assess the viability of the simulation tool for the use in a predictive manner, comprehensive systems as well as to choose the optimal product matches, product analysis methods are needed. Indeed, most of the known methods aim to analyze a product or one product family on the physical level. Different product families, however, may differ largely in terms of the number and nature of components. This fact impedes an efficient comparison and choice of appropriate product family combinations for the production system. A new methodology is proposed to analyze existing products in view of their functional and physical architecture. The aim is to Cluster these products in new assembly oriented product families for the optimization.
The detection of cracks before the failure is highly significant when it comes to safety-relevant structures. Crack detection in metallic samples at high surface temperature is one of the challenging situation in manufacturing industries.
Laser thermography has already proved its detection capability of surface cracks in metallic samples at room temperature. In this work a continuous wave (CW) laser use to generate a laser, which is using to scan the metal surface with notch.
The corresponding heat distribution on the surface monitored using infrared thermal (IR) camera. A simplified 3D model for laser thermography is developed and validated with experimental results. A dedicated image processing algorithm developed to improve the detectability of the cracks. To understand the dependency of surface temperature, laser power, laser scanning speed etc. in defect detection, we carried out parametric studies with our validated model. Here we Report the capability of laser thermography in crack detection at elevated temperature.
The paper deals with the integration of a light emitting diode (LED) into an additive manufactured metal component. Selective laser melting (SLM) and laser metal deposition (LMD) are used. The material used is the chrome-nickel steel 316L. The basic component is manufactured by means of SLM and consists of a solid body and an area with grid structure. The solid body includes a duct in the shape of a groove with a recess for the positioning of the power cable. The LED is embedded in the grid structure via an inlet from the solid body. In further processing, the groove is filled with LMD. Two strategies with different parameter combinations were investigated. It shows that a high energy input near the power cable leads to its destruction. By using multiple parameter combinations during the manufacturing process, this destruction can be prevented. There was a comparison of both strategies with regard to the necessary number of tracks and duration of welding time.
A novel approach for rating fatigue-initiating inclusions in highly demanding steel (INCAFAT)
(2018)
INCAFAT project aimed to improve existing fatigue damage models by establishing the most suitable combination of measurement techniques to characterise harmful inclusion populations in highly demanding steels. The different inclusion assessments carried out confirm that, chemical composition, secondary metallurgy and manufacturing route affect content, nature, size and shape of inclusions. According to the FEM model, inclusions produce an alteration of the stress field in their surrounding region, which can promote a fatigue failure. Experimental work on fatigue testing has demonstrated that depending on the stressed direction fatigue failures in highly demanding steels could be produced by different types of inclusions. Fractography analyses confirmed that meso-inclusions harmful in fatigue cannot be rated by standard methods, nor 10 MHz ultrasonic testing (macro) or micro-cleanness assessments. The necessity of rating these meso-inclusions has led to critical evaluation of Extreme Value Analysis according to ASTM E2283-08 and the development of high frequency immersion ultrasonic testing. EVA methodology based on inclusion width can be applied reliably when principal stress is parallel to the rolling direction. On the contrary, if inclusions are testing in the elongated directions its fails. On the other hand, the guidelines and recommendations for high frequency ultrasonic testing have been compiled in a new European standard draft. This method based on focal beam probes and high-resolution devices is able to provide information on meso-inclusion distribution.
While today, engineers can choose from a wide range of rheology modifying admixtures, in some parts of the world, these are difficult to access, due to their complex processing. However, alternatives can be bio‐based polymers such as polysaccharides from various sources. These are easily accessible all over the world, do not demand for complicated processing, and typically they are more sustainable than many established materials, which are crude oil‐based.
The paper presents the effects of acacia gum, cassava starch and the gum of triumfetta pendrata A. Rich on the rheological performance of cementitious systems. It is shown that acacia gum can be as efficient as polycarboxylate based superplasticisers, cassava starch can reduce the yield stress slightly with little effect on the plastic viscosity, and the gum of triumfet ta pendrata A. Rich increases the thixotropy of cement pastes with plasticizing polymers significantly.
Raman microspectra combine information on chemical composition of plant tissues with spatial information. The contributions from the building blocks of the cell walls in the Raman spectra of plant tissues can vary in the microscopic sub-structures of the tissue. Here, we discuss the analysis of 55 Raman maps of root, stem, and leaf tissues of Cucumis sativus, using different spectral contributions from cellulose and lignin in both univariate and multivariate imaging methods. Imaging based on hierarchical cluster analysis (HCA) and principal component analysis (PCA) indicates different substructures in the xylem cell walls of the different tissues. Using specific signals from the cell wall spectra, analysis of the whole set of different tissue sections based on the Raman images reveals differences in xylem tissue morphology. Due to the specifics of excitation of the Raman spectra in the visible wavelength range (532 nm), which is, e.g., in resonance with carotenoid species, effects of photobleaching and the possibility of exploiting depletion difference spectra for molecular characterization in Raman imaging of plants are discussed. The reported results provide both, specific information on the molecular composition of cucumber tissue Raman spectra, and general directions for future imaging studies in plant tissues.
Die Simulation von Ultraschallausbreitung ist ein wesentliches Hilfsmittel zur Optimierung von Prüfanordnungen und wird zunehmend in der Prüfvorbereitung eingesetzt. Eisenbahnschienen sind Bauteile mit komplexer Geometrie und im eingebauten Zustand eingeschränkter Zugänglichkeit. Bei der Prüfung im Feld entstehen aus der Schienengeometrie komplexe Echosignale mit Formanzeigen, die schwer zu interpretieren sind.
Für das bessere Verständnis der Schallausbreitung in der Eisenbahnschiene wird diese in einem ersten Schritt mit Hilfe verschiedener Ansätze modelliert. Hierbei werden Finite Elemente Methoden und semi-analytischen Modelle verwendet. In einem zweiten Schritt werden die Ergebnisse der Simulationsmodelle einander gegenübergestellt und mit Messungen an realen Schienen verglichen.
Ziel dieser Untersuchungen ist die Validierung von Simulationsverfahren mit Hilfe von Messdatensätzen und Überprüfung der Anwendbarkeit bei der Bewertung von Ergebnissen der Schienenprüfung.
Spektren von gepulsten Röntgenquellen wie Blitzröhren, Linearbeschleuniger (LINACs) oder Betatrons lassen sich in der Literatur nicht finden. Eine gängige Lehrmeinung ist, dass sich solche Spektren nicht messen lassen. Deshalb wurden in Zusammenarbeit mit der Goethe-Universität Frankfurt und neuester Messtechnik diese Problematik untersucht. Es wurde ein CeBr3-Szintillator-Kristall mit einem klassischen Photoelektronenvervielfacher (PMT) und einer analogen Übertragungskette verwendet, der über Stunden Integrationszeit nur einen sehr geringen Untergrund detektiert. Als kritischter Punkt stellte sich die geeignete Kollimierung von Quelle und Detektor bei möglichst großem Abstand heraus. Zu diesem Zweck wurde das verwendete 7 MeV-Betatron in einen 3t-Bleibunker betrieben, der ein Austrittsloch von 1 mm für die erzeugte Röntgenstrahlung besaß. Der Detektor wurde mit einem Densimet-Zylinder abgeschirmt. Damit konnte die Bedingung für die Spektroskopie gepulster Quellen erreicht werden: pro Puls darf nur 1 Photon den Detektorkristall erreichen, damit ohne Pile-up seine Energie vermessen werden kann. Trotz schnellster Elektronik war es nicht möglich, mehere Photonen pro Röntgenpuls (beim Betatron ca. 1 Mikrosekunde) spektral richtig aufzulösen. Die gemessenen Spektren zeigen die erwartete Form, wie sie z.B. mit aRTist simuliert werden können.