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Der Vortrag gibt einen Überblick über aktuelle Möglichkeiten zur Integration von sensorischen Funktionen in Leichtbauwerkstoffe, mit Fokus auf Faserverbundkunststoffe (FVK). Neben den unterschiedlichen Arten der eingesetzten Sensoren werden auch deren Arbeitsweisen, Anwendungsbereiche und Anwendungsbreiten erläutert. Es erfolgt eine Diskussion der Auswirkungen der Integration von Sensoren in die Bauteilstruktur und daraus abgeleitet eine Betrachtung der Vor- und Nachteile der einzelnen Methoden.
Das lernen die Teilnehmer im Vortrag:
Integration von Sensoren in Faserverbundstrukturen
Anwendungen von Sensorik
Auswirkungen der Funktionsintegration auf die Composite
Increased speed, heavier loads, altered material and modern drive systems result in an increasing number of rail flaws. The appearance of these flaws also changes continually due to the rapid change in damage mechanisms of modern rolling stock. Hence, interpretation has become difficult when evaluating non-destructive rail testing results. Due to the changed interplay between detection methods and flaws, the recorded signals may result in unclassified types of rail flaws. Methods for automatic rail inspection (according to defect detection and classification) undergo continual development. Signal processing is a key technology to master the challenge of classification and maintain resolution and detection quality, independent of operation speed. The basic ideas of signal processing, based on the Glassy-Rail-Diagram for classification purposes, are presented herein. Examples for the detection of damages caused by rolling contact fatigue also are given, and synergetic effects of combined evaluation of diverse inspection methods are shown.
Die Ultraschall Phased-Array Technik bietet durch die variable elektronische Steuerung des Schallfeldes gegenüber konventioneller Prüftechnik Vorteile bei vielen Prüfaufgaben, sowohl bei der Datenaufnahme als auch der bildhaften Bewertung. Die mechanisierte Schienenprüfung stellt sehr hohe Anforderungen an die Prüftechnik insbesondere durch die hohen Prüfgeschwindigkeiten von bis zu 20 m/s.
Im Rahmen dieses Vortrags wird evaluiert, welche Lösungsansätze auf Basis der Ultraschall Phased-Array Technik vielversprechend erscheinen für einen Einsatz im Umfeld von Bahn 4.0.
In the last twenty years, components made of fibre-reinforced plastic became a prominently used material in safety-relevant structures. Periodic in-service inspection of these structures using reliable non-destructive testing methods became a relevant issue in the field. The goal of the EMRP-funded project VITCEA (Validated Inspection Techniques for Composites in Energy Applications) aims on the evaluation of the performance of various non-destructive testing methods on the inspection of fibre-reinforced plastics.
In this talk the results of the comparison of different ultrasonic testing methods will be discussed. There are two challenges for the ultrasonic inspection of fibre-reinforced plastics. Firstly, different material properties of the fibre and the resin cause anisotropic acoustical behaviour of the material. Secondly, the physical layout of fibre layers leads to complex structures of fibre-reinforced plastic parts, and thus to a complex acoustical response. Both result in a reduction of the signal to noise ratio and make interpretation of measurement results rather extensive.
During the VITCEA project, the acoustical behaviour of fibre-reinforced plate materials has been simulated. Specimens with artificial flaws for the evaluation of the detection thresholds have been designed and manufactured.
Various mechanized ultrasonic testing methods including phased-array sensors, air-coupled transducers, immersion tank testing and contact technique have been evaluated on the specially designed specimen. Laboratory scale tests and a round robin test have been carried out. The probability of detection and the detection thresholds for each method have been estimated.
Compared to standard ultrasonic testing methods the application of phased arrays offers advantages and flexibility by the electronic steering possibilities to control the transmitted and received sound fields as well as the image based evaluation of the recorded scans. For more than one decade phased array systems have been introduced and used in the railway sector for the inspection of wheelsets in the workshops. Up to the present field applications of phased array systems in rail inspection are rather rare. On the other hand a lot of scientific work on rail testing using phased arrays has been carried out in the recent past.
Mechanized ultrasonic rail inspection poses strong challenges e.g. due to the harsh environment, complex flaw types and high inspection speeds. Different tasks have to be carried out by non-destructive testing ranging from manufacturing inspection of thermite welds to in-service inspection for operational induced flaws in the rail head, rail web and rail foot as well as rolling contact fatigue. This work will give an overview and categorization of different present approaches for rail testing using phased array.
Phased array systems typically offer digital image based inspection results. This make these systems become the perfect candidates to feed inspection data into a modern big data based workflow, using e.g. cloud computing, signal processing and data fusion for recording, positioning and tracking of flaws and artefacts in rails and to gain additional benefit.
Evaluation of promising innovative approaches and solutions for phased array based ultrasonic rail inspection in the frame of “Industry 4.0” will be discussed.
Increased use of high performance steel (HPS) for demanding applications calls for non-destructive ultrasonic testing methods which is covered by standards like SEP 1927 (1) and ASTM E588 (2). Here, an adaption of standards like increasing sensitivity and resolution of ultrasonic testing may be needed in order to improve determination of steel cleanliness.
Modern requirements on standardization in that field have been evaluated during the INCAFAT project “A novel approach for rating fatigue-initiating inclusions in highly demanding steel” which was funded by the European Commission.
Main results of this research show that an adapted standard should be open to different type of specimen due to the diversity in application. This includes a wide range from bars, rings and plates as well as different inspection sensitivities. An adapted standard should be open to the definition of the volume to be investigated and open to be selected by the user. Furthermore, for enhanced resolution the frequency range should be extended to higher frequencies. The use of focal beam probes shall be mandatory and probes should be selected according to the geometry of the specimen. Therefore, calibration procedures have to be improved significantly to allow proper sizing of indications. Indication height shall be directly transferred into an equivalent disc shaped reflector taking distance amplitude curves as well as signal amplitude distribution and signal travel time into account.
A new standard draft proposal taking all these requirements into account has been filed in the frame of the INCAFAT project and is now on discussion.
The Scaled Boundary Finite Element Method is known as an efficient method for the simulation of ultrasonic wave propagation. As to investigate acoustic wave behavior in case of fluid‐structure interaction, a fluid model is implemented in the SBFEM for prismatic structures. To omit coupling terms a displacement‐based formulation is used. Spurious modes, which occur in the solution, are suppressed using a penalty parameter. To verify this formulation dispersion curves obtained with Comsol Multiphysics are compared to results of SBFEM. The results of both methods are in very good agreement