Ingenieurwissenschaften und zugeordnete Tätigkeiten
Filtern
Dokumenttyp
- Vortrag (11)
- Beitrag zu einem Tagungsband (3)
- Zeitschriftenartikel (2)
- Dissertation (1)
- Posterpräsentation (1)
Sprache
- Englisch (16)
- Mehrsprachig (2)
Referierte Publikation
- nein (18) (entfernen)
Schlagworte
- Non-destructive testing (18) (entfernen)
Organisationseinheit der BAM
- 8 Zerstörungsfreie Prüfung (8)
- 8.5 Röntgenbildgebung (4)
- 8.0 Abteilungsleitung und andere (3)
- 5 Werkstofftechnik (2)
- 7 Bauwerkssicherheit (2)
- 7.0 Abteilungsleitung und andere (2)
- 7.1 Baustoffe (2)
- 7.2 Ingenieurbau (2)
- 5.1 Mikrostruktur Design und Degradation (1)
- 5.2 Metallische Hochtemperaturwerkstoffe (1)
Eingeladener Vortrag
- nein (11)
This paper describes a new ultrasonic measuring device called “W-Box”. It was developed based on the requirements of the DFG Forschergruppe (research unit) CoDA for a portable device for monitoring of concrete specimens, models and actual structures using embedded ultrasonic transducers as well as temperature and humidity sensors. The W-Box can send ultrasonic pulses with a variable frequency of 50–100 kHz to one selectable transducer and records signals from up to 75 multiplexed channels with a sample rate of 1 MHz and a resolution of 14 bits. In addition, it measures temperature and humidity with high accuracy, adjustable amplification, restarts automatically after a power failure and can be fully controlled remotely. The measured data are automatically stored locally on-site data quality checks and transferred to remote servers. The comparison of the W-Box with a laboratory setup using commercial devices proves that it is equally reliable and precise, at much lower cost. The W-Box also shows that their measurement capacities, with the used embedded ultrasonic transducers, can reach above 6 m in concrete.
Fibre-Matrix-Debonding in glass fibre reinforced dental posts can play an important role for their mechanical performance and long term stability… We show that synchrotron X-ray refraction radiography (SXRR) allows analysis of large samples (up to several millimetres) without compromising the detectability of sub micrometer defects.
In diesem Vortrag wird am Beispiel magnetischer Werkstoffe zur Energiewandlung gezeigt, wie röntgentomographische Untersuchungen zur Strukturaufklärung in Kompositen und Massivproben beitragen können. Die Bauteile werden zerstörungsfrei geprüft, um Risse, Poren und andere Defekte und ihren Einfluss auf die funktionellen Eigenschaften dreidimensional und rechtzeitig im Lebenszyklus des Werkstoffs zu charakterisieren. Kombiniert man Mikrotomographie mit anderen Methoden der magnetischen Werkstoffcharakterisierung, lassen sich einzigartige Aussagen über den Aufbau und die funktionellen Eigenschaften treffen.
Using magnetic materials for energy conversion as an example, this lecture shows how X-ray tomography investigations can contribute to structure elucidation in composites and solid samples. The components are tested non-destructively in order to characterize cracks, pores and other defects and their influence on the functional properties three-dimensionally and in good time in the life cycle of the material. If you combine microtomography with other methods of magnetic material characterization, you can make unique statements about the structure and the functional properties.
To date, there are very few technologies available for the conversion of low-temperature waste heat into electricity. Thermomagnetic generators are one approach proposed more than a century ago. Such devices are based on a cyclic change of magnetization with temperature. For thermomagnetic materials, we used a commercial magnetocaloric alloy with a transition temperature of 300 K.
In diesem Vortrag wird am Beispiel magnetischer Werkstoffe zur Energiewandlung gezeigt, wie röntgentomographische Untersuchungen zur Strukturaufklärung in Kompositen und Massivproben beitragen können. Die Bauteile werden zerstörungsfrei geprüft, um Risse, Poren und andere Defekte und ihren Einfluss auf die funktionellen Eigenschaften dreidimensional und rechtzeitig im Lebenszyklus des Werkstoffs zu charakterisieren. Kombiniert man Mikrotomographie mit anderen Methoden der magnetischen Werkstoffcharakterisierung, lassen sich einzigartige Aussagen über den Aufbau und die funktionellen Eigenschaften treffen.
Statistically the mean time between damage events on rotor blades is 6 years (Deutscher Windenergie Report 2006). Due to imperfection in the production the shell structures get cracks after a few years fare before the designed life time. A shell test rig was built at BAM for efficient research on the effects of defects in production.
In-situ and ex-situ NDT give a better understanding from degradation processes in composite materials.
With advanced methods in the research on the fatigue behaviour of FRP it was found a load level of infinite life for GFRP and CFRP. This is in the range of typical strain values of airliners and rotor blades in normal operation.
Due to the fibre-composite nature NDT techniques have to be suitable to a wide length scale to image micro cracking as well as bigger defects. Therefore different techniques have to be applied and developed.
An overview of the BAM funed Focus Area Materials Project "AGIL" will be presented. AGIL focussed on the stdiy of the ageing characteristics of additively manufactured austenitic stainless steel with a "powder to mechanical failure" Approach. Recent Highlights are presented and a perspective for future studies.
The worldwide spread of windfarms brings new challenges, especially for concrete structures as a part of towers, connecting joints and foundations of wind turbines. High-cyclic loadings in such structures lead to a high relevance of the subject of fatigue. A proper assessment of the fatigue strength of concrete demands therefore a basis of reliable experimental data and the development of standardized testing methods. This article presents first results of an ongoing research program of BAM (Bundesanstalt für Materialforschung und -prüfung) which is a part of a joint project (WinConFat) funded by the German Federal Ministry for Economic Affairs and Energy. The subproject investigates the effects of size and slenderness of the specimens on the fatigue behaviour of high strength concrete at different stress levels. Not only the fatigue strength, but also the fatigue process itself is monitored by means of several measurement methods. Strain measurements are used to calculate the load dependent elastic modulus in the fatigue hysteresis as indicators for fatigue development. Furthermore, the application of non-destructive methods like acoustic emission analysis and ultrasonic measurement in laboratory tests gives a deeper insight into damage processes under cyclic loading. The results shall be used to improve design rules for concrete members under fatigue load and to develop or improve non-destructive techniques for in-service structural health monitoring.
The worldwide spread of windfarms brings new challenges, especially for concrete structures as a part of towers, connecting joints and foundations of wind turbines. High-cyclic loadings in such structures lead to a high relevance of the subject of fatigue. A proper assessment of the fatigue strength of concrete demands therefore a basis of reliable experimental data and the development of standardized testing methods. This article presents first results of an ongoing research program of BAM (Bundesanstalt für Materialforschung und -prüfung) which is a part of a joint project (WinConFat) funded by the German Federal Ministry for Economic Affairs and Energy. The subproject investigates the effects of size and slenderness of the specimens on the fatigue behaviour of high strength concrete at different stress levels. Not only the fatigue strength, but also the fatigue process itself is monitored by means of several measurement methods. Strain measurements are used to calculate the load dependent elastic modulus in the fatigue hysteresis as indicators for fatigue development. Furthermore, the application of non-destructive methods like acoustic emission analysis and ultrasonic measurement in laboratory tests gives a deeper insight into damage processes under cyclic loading. The results shall be used to improve design rules for concrete members under fatigue load and to develop or improve non-destructive techniques for in-service structural health monitoring.
While additive manufacturing (AM) is blossoming in nearly every industrial field, and the most different process are being used to produce components and materials, little attention is paid on the safety concerns around AM materials and processes.
Leveraging on our leading expertise in non-destructive testing (NDT) and materials characterization, we approach AM at BAM under two important viewpoints: first the on-line monitoring of the process and of the product, second the evolution of the (unstable) microstructure of AM materials under external loads.
These two subjects are the core of the two new-born internal projects ProMoAM and AGIL, respectively.
A detailed view of the goals and the organization of these two projects will be given, together with the expected output, and some preliminary results.
Defect recognition in CFRP components using various NDT methods within a smart manufacturing process
(2017)
The manufacturing process of carbon fiber reinforced polymer (CFRP) components is playing a more and more significant role when looking at the increasing amount of CFRPs used in industries today. The monitoring of the manufacturing process and hence the reliability of the manufactured products, is one of the major challenges we need to face in the near future. Common defects which arise during manufacturing are e.g. porosity and voids which may lead to delaminations during operation and under load. To find those defects in an early stage of the manufacturing process is of huge importance for the safety and reliability of the finished products, as well as of significant impact from an economical point of view. In this study we present various NDT methods which are applied to similar CFRP laminate samples in order to detect and characterize defective volume. Besides ultrasound, thermography and eddy current, different x-ray methods like radiography, laminography and computed tomography are used to investigate the samples. These methods are compared with the intention to evaluate their capability to reliably detect and characterize defective volume. Beyond the detection of flaws, we also investigate possibilities to combine various NDT methods within a smart manufacturing process in which the decision which method to apply is made by the process itself. Is it possible to design an in-line or at-line testing process which can recognize defects reliably and reduce testing time and costs? This study aims to show up opportunities of designing a smart NDT process synchronized to the production based on the ideas of smart production (Industry 4.0). A set of defective CFRP laminate samples and different NDT methods were used to demonstrate how effective defects are recognized and how communication between interconnected NDT sensors and the manufacturing process could be organized.
This paper focuses on the aspect on how damage evolution processes in composite materials and structures including matrix fracture, delamination, fibre-matrix debonding, and fibre fracture can be detected by taking advantage of the material’s inherit mechanical properties. These properties can be described on the basis of non-linear mechanical phenomena measurable as an inert frequency response signal. The approach is proposed as a means for residual life structural assessment specifically in the context of VHCF.
Grating interferometric set-ups have been established in the last decade. They are promising candidates to obtain enhanced image contrast from weakly absorbing micro and nano structures. They are based on X-ray refraction and near-field diffraction using the Talbot effect.
At the expense of taking multiple images, Talbot-Lau grating interferometry allows separating the absorption, refraction, and scattering contributions by analysing the disturbances of a phase grating interference pattern. Contrary to other refraction enhanced methods, this technique can be applied using conventional X-ray tubes (divergent, polychromatic source). This makes it attractive to solve typical non-destructive testing problems.
We investigated the efficiency of phase gratings, i.e. the visibility (the amplitude of oscillations) upon variation of propagation distance and phase grating rotation around an axis parallel to the grid lines. This grating rotation changes the grating shape (i.e. the distributions of phase shifts). This can yield higher visibilities than derived from rectangular shapes.
Our study includes experimental results obtained from synchrotron radiation, as well as simulations for monochromatic radiation. The advantages of Talbot-Lau interferometry are demonstrated at the example of glass capillaries.
The detection and characterization of surface cracks in steel specimens prior to damage is a technologically and economically highly significant task and is of utmost importance when it comes to safety-relevant structures. In steel production where steel billets at high temperatures have to be inspected while moving a number of well-established NDT methods cannot be applied. Laser thermography however is a promising candidate to serve as a fast, non-contact and remote tool in this case. We present a study that shows that the crack detection capabilities of laser thermography can be extended also to specimens at high temperature. A combination of inductive and laser heating allows to systematically study the contrast formation as well as the optimization of the important measurement parameters. The experiments are accompanied by FEM simulations that provide a better insight of the physical correlations and support the experimental developments. The aim of these studies is to develop a system with high inspection speed and detection performance to be in-line operated under the hostile environment of steel production lines.
Non-destructive testing (NDT) is regarded as one of the key elements in ensuring quality of engineering systems and their safe use. A failure of NDT to detect critical defects in safetyrelevant components, such as those in the nuclear industry, may lead to catastrophic consequences for the environment and the people. Therefore, ensuring that NDT methods are capable of detecting all critical defects, i.e. that they are reliable, is of utmost importance. Reliability of NDT is affected by human factors, which have thus far received the least amount of attention in the reliability assessments. With increased use of automation, in terms of mechanised testing (automation-assisted inspection and the corresponding evaluation of data), higher reliability standards are believed to have been achieved. However, human inspectors, and thus human factors, still play an important role throughout this process, and the risks involved in this application are unknown. The overall aim of the work presented in this dissertation was to explore for the first time the risks associated with mechanised NDT and find ways of mitigating their effects on the inspection performance. Hence, the objectives were to (1) identify and analyse potential risks in mechanised NDT, (2) devise measures against them, (3) critically address the preventive measures with respect to new potential risks, and (4) suggest ways for the implementation of the preventive measures. To address the first two objectives a risk assessment in form of a Failure Modes and Effects Analysis (FMEA) was conducted (Study 1). This analysis revealed potential for failure during both the acquisition and evaluation of NDT data that could be assigned to human, technology, and organisation. Since the existing preventive measures are insufficient to defend the system from identified failures, new preventive measures were suggested. The conclusion of the study was that those preventive measures need to be carefully considered with respect to new potential risks, before they can be implemented, thus serving as a starting point for further empirical studies. To address the final two objectives, two preventive measures, i.e. human redundancy and the use of automated aids in the evaluation of NDT data, were critically assessed with regard to potential downfalls arising from the social interaction between redundant individuals and the belief in the high reliability of automated aids. The second study was concerned with the potential withdrawal of effort in sequential redundant teams when working collectively as opposed to working alone, when independence between the two redundant individuals is not present. The results revealed that the first redundant inspector, led to believe someone else will conduct the same task afterwards, invested the same amount of effort as when working alone. The redundant checker was not affected by the information about the superior experience of his predecessor and—instead of expected withdrawal of effort—exhibited better performance in the task. Both results were in contradiction to the hypotheses, the explanations for which can be found in the social loafing and social compensation effects and in the methodological limitations. The third study examined inappropriate use of the aid measured in terms of (a) agreement with the errors of the aid in connection to the frequency of verifying its results and in terms of (b) the overall performance in the task. The results showed that the information about the high reliability of the aid did not affect the perception of that aid’s performance and, hence, no differences in the actual use of the aid were to be expected. However, the participants did not use the aid appropriately: They misused it, i.e. agreed with the errors committed by the aid and disused it, i.e. disagreed with the correct information provided by the aid, thereby reducing the overall reliability of the aid in terms of sizing ability. Whereas aid’s misuse could be assigned to low propensity to take risks and reduced verification behaviour because of a bias towards automation, the disuse was assigned to the possible misunderstanding of the task. The results of these studies raised the awareness that methods used to increase reliability and safety, such as automation and human redundancy, can backfire if their implementation is not carefully considered with respect to new potential risks arising from the interaction between individuals and complex systems. In an attempt to minimise this risk, suggestions for their implementation in the NDT practice were provided.
Elastic wave propagation of ultrasound in bituminous road surfaces - simulations and measurements
(2015)
Maintenance costs of road infrastructure are increasing steadily. The main cause of this is the nearly exponential increase of traffic during the last decades. Adverse environmental impacts on infrastructure get more and more important as well. Therefore, it is important to determine how limited financial resources can be directed with an optimum pay-out. Often a decision has to be made whether existing structures have to be rebuilt or repaired based on the condition of the structures. The present study takes first steps towards the usage of low-frequency ultrasound as a tool to evaluate the road condition. The overall aim is to derive a prediction model for future road conditions. In order to better understand and interpret recorded wave fields simulations of elastic wave propagation in layered and scattering road models have been performed. The study combined investigations in the laboratory with field measurements. In a series of extensive laboratory tests with different asphalt mixtures characteristic wave properties have been derived. Travel time (resp. velocity) as important material parameter has been investigated for different wave types, different centre frequencies and at various temperatures. An investigation of the directivity of wave radiation in the heterogeneous asphalt bodies led to an estimate of the related disturbing influences. Based on the laboratory results field measurements were performed on a real road and the records were processed to identify layers, propagation speeds and attenuation. The results were verified by a series of simulations.