8.0 Abteilungsleitung und andere
Filtern
Erscheinungsjahr
- 2020 (24) (entfernen)
Dokumenttyp
- Zeitschriftenartikel (24) (entfernen)
Schlagworte
- Thermography (6)
- Additive Manufacturing (3)
- Infrared thermography (3)
- Laser thermography (3)
- Numerical simulation (3)
- Process monitoring (3)
- Compressed sensing (2)
- Delamination (2)
- GFRP (2)
- Laser powder bed fusion (L-PBF) (2)
Organisationseinheit der BAM
- 8 Zerstörungsfreie Prüfung (24)
- 8.0 Abteilungsleitung und andere (24)
- 9 Komponentensicherheit (6)
- 9.3 Schweißtechnische Fertigungsverfahren (6)
- 8.5 Röntgenbildgebung (3)
- 1 Analytische Chemie; Referenzmaterialien (1)
- 1.4 Prozessanalytik (1)
- 5 Werkstofftechnik (1)
- 5.1 Mikrostruktur Design und Degradation (1)
- 6 Materialchemie (1)
Paper des Monats
- ja (1)
Laser excited super resolution thermal imaging for nondestructive inspection of internal defects
(2020)
A photothermal super resolution technique is proposed for an improved inspection of internal defects. To evaluate the potential of the laser-based thermographic technique, an additively manufactured stainless steel specimen with closely spaced internal cavities is used. Four different experimental configurations in transmission, reflection, stepwise and continuous scanning are investigated. The applied image post-processing method is based on compressed sensing and makes use of the block sparsity from multiple measurement events. This concerted approach of experimental measurement strategy and numerical optimization enables the resolution of internal defects and outperforms conventional thermographic inspection techniques.
The quality of additively manufactured (AM) parts is determined by the applied process parameters used and the properties of the feedstock powder. The influence of inner gas pores in feedstock particles on the final AM product is a phenomenon which is difficult to investigate since very few non-destructive measurement techniques are accurate enough to resolve the micropores.
3D X-ray computed tomography (XCT) is increasingly applied during the process chain of AM parts as a non-destructive monitoring and quality control tool and it is able to detect most of the pores.
However, XCT is time-consuming and limited to small amounts of feedstock powder, typically a few milligrams. The aim of the presented approach is to investigate digital radiography of AM feedstock particles as a simple and fast quality check with high throughput. 2D digital radiographs were simulated in order to predict the visibility of pores inside metallic particles for different pore and particle diameters. An experimental validation was performed. It was demonstrated numerically and experimentally that typical gas pores above a certain size (here: 3 to 4.4 µm for the selected X-ray setup), which could be found in metallic microparticles, were reliably detected by digital radiography.
Additive manufacturing offers a range of novel applications. However, the manufacturing process is complex and the production of almost defect-free parts with high reliability and durability is still a challenge. Thermography is a valuable tool for process surveillance, especially in metal additive manufacturing processes. The high process temperatures allow one to use cameras usually operating in the visible spectral range. Here, we compare the results of measurements during the manufacturing process of a commercial laser metal deposition setup using a mid wavelength infrared camera with those from a short wavelength infrared camera and those from a visual spectrum high-speed camera with band pass filter in the near infrared range.
Recording the temperature distribution of the layer under construction during laser powder bed fusion (L-PBF) is of utmost interest for a deep process understanding as well as for quality assurance and in situ monitoring means. While having a notable number of thermal monitoring approaches in additive manufacturing (AM), attempts at temperature calibration and emissivity determination are relatively rare. This study aims for the experimental temperature adjustment of an off-axis infrared (IR) thermography setup used for in situ thermal data acquisition in L-PBF processes. The temperature adjustment was conducted by means of the so-called contact method using thermocouples at two different surface conditions and two different materials: AISI 316L L-PBF bulk surface, AISI 316L powder surface, and IN718 powder surface. The apparent emissivity values for the particular setup were determined. For the first time, also corrected, closer to real emissivity values of the bulk or powder surface condition are published. In the temperature region from approximately 150 °C to 580 °C, the corrected emissivity was determined in a range from 0.2 to 0.25 for a 316L L-PBF bulk surface, in a range from 0.37 to 0.45 for 316L powder layer, and in a range from 0.37 to 0.4 for IN718 powder layer.
Crack detection in steel bars at high surface temperatures is a critical problem in any manufacturing industry. Surface breaking cracks are the major problems during the billet casting. Many NDT techniques are proven its capability in crack detection at room temperature. Here, we are demonstrating the possibility of exposure of cracks using laser line thermography at higher surface temperatures (up to 600 °C). A continuous-wave (CW) laser is used to excite the sample kept at higher surface temperatures. The temperature distribution over the sample due to the laser line scanning is captured using a temperature calibrated infrared (IR) thermal camera. The response of the sample temperature in crack detection is investigated using a validated FE model. The impact of the oxide layer in crack detection is investigated by using two types of samples; one without any oxide layer and the second is with the oxide layer. The influence of laser power in the detection of defects at high temperatures is studied. 3D numerical models were developed for the cases; when the sample is with oxide layer and without any oxide layer for a better understanding of physics. The surface temperature rise due to laser heating is higher for the scaled sample compared to the no-scale sample. The presence of the oxide layer above the parent metal will reduce the reflectivity of the surface. Lower reflectivity will lead to increased absorption of incident energy so that the surface temperature rise will be higher than the surface with no scale. Thermal contrast linearly depends on laser power, which means higher laser power will increase the defect detectability even at a higher surface temperature.
Magnetocaloric composite wires have been studied by pulsed-field measurements up to μ0ΔH = 10 T with a typical rise time of 13 ms in order to evaluate the evolution of the adiabatic temperature change of the core, ΔTad, and to determine the effective temperature change at the surrounding steel jacket, ΔTeff, during the field pulse. An inverse thermal hysteresis is observed for ΔTad due to the delayed thermal transfer. By numerical simulations of application-relevant sinusoidal magnetic field profiles, it can be stated that for field-frequencies of up to two field cycles per second heat can be efficiently transferred from the core to the outside of the jacket. In addition, intense numerical simulations of the temperature change of the core and jacket were performed by varying different parameters, such as frequency, heat capacity, thermal conductivity and interface resistance in order to shed light on their impact on ΔTeff at the outside of the jacket in comparison to ΔTad provided by the core.
Removal of Etalon Features in the Far-Infrared–Terahertz Transmittance Spectra of Thin Polymer Films
(2020)
Etalon features in infrared spectra of stratified samples, their influence on the interpretation and methods to circumvent their presence in infrared spectra have been in discussion for decades. This paper focuses on the application of a method originally developed to remove interference fringes in the mid-infrared spectra for far-infrared Fourier transform spectroscopy on thin polymer films. We show that the total transmittance-reflectance technique, commonly used for mid-infrared, also works successfully in the far infrared spectral range where other approaches fail. Experimental spectra obtained by such technique are supported by model calculations and reveal the possibility and limits to obtain almost undisturbed far-infrared spectra which are suitable to determine low energy vibrations of ionomer salts under certain sample conditions.
Rapid cooling rates and steep temperature gradients are characteristic of additively manufactured parts and important factors for the residual stress formation. This study examined the influence of heat accumulation on the distribution of residual stress in two prisms produced by Laser Powder Bed Fusion (LPBF) of austenitic stainless steel 316L. The layers of the prisms were exposed using two different border fill scan strategies: one scanned from the centre to the perimeter and the other from the perimeter to the centre. The goal was to reveal the effect of different heat inputs on samples featuring the same solidification shrinkage. Residual stress was characterised in one plane perpendicular to the building direction at the mid height using Neutron and Lab X-ray diffraction. Thermography data obtained during the build process were analysed in order to correlate the cooling rates and apparent surface temperatures with the residual stress results. Optical microscopy and micro computed tomography were used to correlate defect populations with the residual stress distribution. The two scanning strategies led to residual stress distributions that were typical for additively manufactured components: compressive stresses in the bulk and tensile stresses at the surface. However, due to the different heat accumulation, the maximum residual stress levels differed. We concluded that solidification shrinkage plays a major role in determining the shape of the residual stress distribution, while the temperature gradient mechanism appears to determine the magnitude of peak residual stresses.
Material qualification for laser powder bed fusion (L-PBF) processes are often based on results derived from additively manufactured (AM) bulk material or small density cubes, although it is well known that the part geometry has a tremendous influence on the heat flux and, therefore, on the thermal history of an AM component. This study shows experimentally the effect of simple geometrical obstructions to the heat flux on cooling behavior and solidification conditions of 316L stainless steel processed by L-PBF. Additionally, it respects two distinct inter layer times (ILT) as well as the build height of the parts. The cooling behavior of the parts is in-situ traced by infrared (IR) thermography during the built-up. The IR signals reveal significant differences in cooling conditions, which are correlated to differences in melt pool geometries. The acquired data and results can be used for validation of computational models and improvements of quality assurance.
Thanks to its good strength/mass ratio, a glass fibre reinforced plastic (GFRP) composite is a common material widely used in aviation, power production, automotive and other industries. In its turn, active infrared (IR) nondestructive testing (NDT) is a common inspection technique for detecting and characterizing structural defects in GFRP. Materials to be tested are typically subjected to optical heating which is supposed to occur on the material surface. However, GFRP composite is semitransparent for optical radiation of both visual and IR spectral bands. Correspondingly, the inspection process represents a certain combination of both optical and thermal phenomena. Therefore, the known characterization algorithms based on pure heat diffusion cannot be applied to semi-transparent materials. In this study, the phenomenon of GFRP semi-transparency has been investigated numerically and experimentally in application to thermal NDT. Both Xenon flash tubes and a laser have been used for thermal stimulation of opaque and semi-transparent test objects. It has been shown that the Penetration of optical heating radiation into composite reduces detectability of shallower defects, and the signal-to-noise ratio can be enhanced by applying the technique of thermographic signal reconstruction (TSR). In the inspection of the semi-transparent GFRP composite, the most efficient has been the laser heating followed by the TSR data processing. The perspectives of defect characterization of semi-transparent materials by using laser heating are discussed. A neural network has been used as a candidate tool for evaluating defect depth in composite materials, but its training should be performed in identical with testing conditions.