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Paper des Monats
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Eine auf den Werkstoff und seine Umwelteinflüsse bezogene Festigkeitsforschung muß auf Vorgänge im elastischen und im überelastischen Beanspruchungsbereich in gleicher Weise bezogen sein. Merkformeln für mechanische Untersuchungen, Parameterwahl und mögliche Zusammenhänge erleichtern die jeweilige Problemstellung, die Kombination entsprechender Untersuchungsverfahren und die Auswahl oder die Entwicklung geeigneter Prüf-, Registrier- und Auswertgeräte.
Beispiele aus der mechanischen Werkstoffprüfung lassen Vorstellungen ableiten über die Vielfalt und die unterschiedlichen Leistungen solcher Untersuchungseinrichtungen. Vor allem interessieren dabei die Beziehungen zwischen der Formänderung und dem Formänderungswiderstand von Proben aus Stoffen und Gemengen und von Konstruktionen bei ein- und mehrachsiger, elastischer und überelastischer, bei zügiger, ruhender, schwingender und stoßförmiger Beanspruchung bis zum Versagen durch unzulässig große Gestaltänderungen, durch Erschöpfen des Formänderungsvermögens, durch Zerrütten der Werkstoffestigkeit oder durch spröden Bruch. Daraus folgt, daß umfangreiche Stoff- und Materialdaten als Grundlage für die zuverlässige und erfolgreiche Prüfung von Werkstoffen und daraus meist im Verbund hergestellten Konstruktionen verfügbar sein sollten. Dafür wiederum ist erforderlich die Beschreibung der Werkstoffe selbst, der für ihr Festigkeitsverhalten typischen Beanspruchungen von zusätzlich einwirkenden Variablen und von Parametern einschließlich der Besonderheiten langer Einwirkungsdauer. Mit dem Denken in solchen Zusammenhängen können grundsätzliche Folgerungen für die Beurteilung und für die Entwicklung von Prüfmaschinen und Geräten gewonnen werden.
As an approach towards more rough industrial laser welding applications, the Nd:YAG laser welding process has been coupled to the plasma powder welding process for the first time. Process stabilities have been achieved by such hybrid welding which are even better than those known from previous coupling of the laser process with gas metal arc welding (GMAW), for instance.
The present contribution focuses on the technology and potentials of the novel laser hybrid welding technique and addresses the realisation and the perspectives for practical applications. The experimental results demonstrate that the new process coupling enables welding of austenitic stainless steels in the thickness range between 3 mm and 8 mm at various weld geometries and joint configurations and at welding speeds exceeding 2 m/min. In addition it has been proven that the laser plasma powder arc welding (LPPAW) technique can also be applied to out-of-position conditions. Continuous advancement of the welding equipment ensures a high gap bridging ability and levelling of misalignment due to higher powder feeding rates. The recent development of a new plasma powder torch even provides a higher efficiency of powder feeding and guarantees smoth weld surfaces. Up to the present, the investigations demonstrated that the novel laser plasma powder hybrid welding technique offers all perspectives for application in pipe fabrication, ship building and offshore as well as transportation industry.
The increasing application of supermartensitic steels for welded pipelines is an economical alternative to the hitherto used higher-alloyed materials in the North Sea oil and gas indus-try. Failure in such constructions must at any rate be excluded for economical and ecologi-cal reasons. The application of these steels for the transport of corrosive mixtures may, however, involve hydrogen pickup with subsequent hydrogen-assisted stress corrosion cracking. It is therefore necessary not only to assure the weldability, but particularly to have best possible knowledge of the service behaviour and of the failure risk. In order to ensure the transferability of test results to real joined components, innovative test methods are in-creasingly required to be incorporated into a closed test sequence. It will be demonstrated how it is possible to gain significant advantages from the direct comparison between ex-perimentally determined results from component weld tests on the one hand and material-specific data from small-scale tests on the other hand and numerical simulations. These data that have now been made available are of major importance for industrial applications and are considered to provide a sound basis for realistic lifetime assessments.
In the last decade, high-strength fine grained steels and welding consumables have gained a strong raise of application ranging from mobile cranes to bridge constructions. However, the cracking susceptibility of these steels increases significantly in correspondence with the achieved improvements in yield strength and the loss in plastic deformation reserves.
In order to determine this behavior a series of different standardized cold cracking tests has been developed. One remaining major problem of these tests is the uncertainty about the quantitative intensity of the restraint conditions as well as the corresponding welding residual stresses.
Consequently, the comparison of different tests and welding conditions as well as the transferability of the results onto real parts is difficult at best. The main topic of this paper is the analysis of the restraint conditions and their link with the welding induced residual stresses. The importance of the given standardized selfrestrained tests and first results about the transferability of
results onto real parts are discussed. The influence of the test specimen geometry on the restraint conditions of the test is investigated for a selected test with numerical Simulation using commercial FEA software. Additionally, the residual stresses caused by the welding process are measured and linked with the restraint conditions which are defined mainly by the geometry parameters.
Finally the transferability of the selected cold cracking test results is validated experimentally. The test results of a multilayer weld on high-strength fine grained steel of real size weldments are investigated. For these experiments a 16 MN large scale testing facility is used which is capable of applying the high reaction forces and clamping conditions found at large scale demonstrator parts.
The results show the importance of the quantitative knowledge of the restraint conditions and the welding residual stresses on the cold cracking resistance.
Within the last decade, silicon drift detectors (SDD) systems have become more and more popular in the field of energy-dispersive spectroscopy (EDS). The main characteristic of the SDDs is their extremely high pulse load capacity of up to 750,000 counts per second at good or reasonable energy resolution (<123eV Mn-Kα, <46eV C-Kα at 100.000 cps). These properties in conjunction with electron backscatter diffraction (EBSD) techniques and modern data processing make a range of innovative analysis options possible, not only high speed mapping but also hyperspectral imaging techniques.
The use of energetic materials as a main fuel in high temperature process
industries are not known to the scientific community as such. This paper
highlights some of the features and advantages of using organic peroxides
especially di-tert-butyl peroxide (DTBP) in high temperature process industries.
The feasibility of using DTBP as a main or supporting fuel in process industries
have also been justified with the help of Computational Fluid Dynamics (CFD)
simulations. For peroxides requirement of less fuel and air for the same amount
of heat flux has been shown. The resulted emission from the combustion of
DTBP is also discussed.
Meteorites are a unique and inspiring material for microstructural studies because if their very specific genesis. Iron meteorites have been formed under unimaginable cooling rates of a few ten Kelvins per million years so that the observable transformation of the formerly huge Fe-Ni single crystals of taenite occurred under nearly-equilibrium conditions. Octahedrites (meteorites having a Ni content between 6...15%) are characterized by ribbons of the low-temperature Fe-Ni phase kamacite separated by rims of residual taenite. This very specific feature is known as Widmanstaetten structure and has been investigated by synchrotron radiation in order to cover a higher volume fraction for a statistically relevant description of orientation relationships. However, plessite – a microstructure mainly consisting of the same phases – reflects the orientation relationship between kamacite and taenite as well. For their characterization, a scanning electron microscope is very suitable in order to investigate crystal orientations or identify phases. Despite the apparently ideal formation circumstances of iron meteorites, Ni concentration profiles prove non-equilibrium conditions. Combined EDS (energy dispersive spectroscopy) and EBSD (electron backscatter diffraction) measurements at a selected plessitic region of the Cape York iron shows that a correlation exists between Ni-concentration and the locally detected orientation relationship.
This study focuses on concrete flow in presence of obstacles and develops a mathematical model and a computational approach for SCC flow through reinforced formworks. In order to decrease high computational times needed to simulate castings through reinforced elements, an innovative approach to model the reinforced sections as porous media is proposed here. In the previous work, this numerical model is proved able to simulate the free-surface flow of non-Newtonian fluids through the reinforcement networks. In the present study, the applicability of the model on the concrete flow will finally be proved. The large-scale form-filling experiments with SCC will be conducted and the experiments will be simulated using the proposed numerical model. The numerical model will then be validated through the comparison of the experimental results and the results of the numerical simulations.
Fraktographischen Daten aus Schadensanalysen, Vergleichsversuchen und Vorhaben könnten der Fachöffentlichkeit im Bereich Fraktographie zur Verfügung gestellt werden, sofern das Urheberrecht es zulässt und außerdem ein geeignetes Medium existiert. Ein solches Medium könnte eine offene fraktographische online-Datenbank sein. Eine solche wird im Rahmen der AG Fraktographie im DVM-DGM Gemeinschaftsausschuss "Rasterelektronenmikroskopie in der Materialprüfung" zurzeit erarbeitet.
Fibre Reinforced Plastics (e.g. CFRP, GFRP) characteristically show nonlinear stress-strain behaviour due to intralaminar shear loading. The determination of the in-plane shear stiffness and strength for this class of material is difficult and common test standards and methods of analysis are partially inaccurate. The identification of the in-plane shear properties was made with an especial designed “picture frame test device” which enables shear loading up to 950N/mm. Therefore the strength limit can be reached at specimens with adequate thickness and a high safety factor against buckling. Due to the chosen design the maximum of the shear loading and the final failure occur in the centre of the specimen. The experiments match with the numerical analysis.
Today’s light weight design trends lead to a growing application of high-strength structural steels (yield strength ≥ 690 MPa). The mechanical properties of the weld and the component safety have to meet the increased requirements of these steel grades. However, high residual stresses in welded components are detrimental to their safety and integrity. Analyses concerning weld stresses in high-strength steels welded under component related restraint conditions revealed that heat control significantly affects global and local stresses. This occurs especially in highly restrained joints due to superimposing local and global stresses and may cause crack-critical stress-levels. In this study weld tests were performed with plates of high-strength steel in a special test facility. The experimental setup allowed transferring defined restraint conditions to the test welds similarly to real components. Temperature and reaction forces due to restraint were observed online while welding and cooling of multilayer-component MAG-welds. Mobile X-ray diffraction was used for local stress determination in the weld seam areas of the restrained specimens. It was found that interpass temperature has a major influence on the local and global welding forces and stresses. Thus, among the analysed results especially transverse residual stresses of the heat affected zone were strongly affected.
Emergency response units increasingly use pressure cylinders made from fibre composites for breathing air as elements of personal protective equipment (PPE). Such applications expose the composite cylinders to harsh temperature and handling conditions. At least in Europe, standards have been used for certifying PPE, which are designed and mandatory for the approval of pressure receptacles for the transport of dangerous goods. Therefore, service conditions specific to PPEs are not accounted for in these standards. In this paper, BAM (Federal Institute for Materials Research and Testing) investigates the residual safety of a composite cylinder design at the end of their designated service life of 15 years. The cylinders (test pressure PH 450 bars; 6.8 Litres) are of one design type with aluminium liner and fully wrapped with carbon fibres, which is commonly considered a “Type III” cylinder. All cylinders were used as PPE by the Berlin fire department and randomly picked in three samples of 25 cylinders each before tested.
At BAM, the cylinder samples underwent hydraulic load cycle tests (LCT), conventional burst tests (BT) and so called slow burst tests (SBT). A concept for quantification of strength degradation already introduced by BAM was applied. This concept is based on a probabilistic assessment of the average strength and scatter of each sample of cylinders. The strength distributions of the used PPEcylinders is shown and analysed. Some unexpected effects are shown and a refinement of the statistical assessment is introduced.
Nanotechnology is one of the key technologies of the 21st century. The exploitation of 'new' effects that arise from materials structured on the nano-scale has also been proposed successfully for flame retardancy of polymers since the end of the 90s. Of all of the approaches these include, at this time the use of nanocomposites offers the best potential for industrial application, also some other ideas are sketched, such as using electrospun nanofibers mats or layer-by-layer deposits as protection coatings, as well as sub-micrometer multilayer coatings as effective IR-mirrors. The general phenomena, inducing a flow limit in the pyrolysing melt and changing the fire residue, are identified in nanocomposites. Key experiments are performed such as quasi online investigation of the protection layer formation to understand what is going on in detail. The flame retardancy mechanisms are discussed and their impact on fire behaviour quantified. With the latter, the presentation pushes forward the state of the art. For instance, the heat shielding is experimentally quantified for a layered silicate epoxy resin nanocomposite proving that it is the only import mechanism controlling the reduction in peak heat release rate in the investigated system for different irradiations. The flame retardancy performance is assessed comprehensively illuminating not only the strengths but also the weak points of the concepts. Guidelines for materials development are deduced and discussed. Apart from inorganic fillers (layered silicate, boehmite, etc.) not only carbon nanoobjects such as multiwall carbon nanotubes, multilayer graphene and graphene are investigated, but also nanoparticles that are more reactive and harbor the potential for more beneficial interactions with the polymer matrix.
Concrete of today has only little in common with the traditional concrete used a few decades ago. It has become a high performance material, which can be adjusted for high performance applications and according to ultimate user specifications. The reason for the rapid evolvement was the increasing awareness about how the rheology of concrete can be improved without negatively affecting the mechanical properties of concrete by chemical admixtures.
From the last decades the earth construction has a growing interest due to the high sustainability (low C02 emissions), thermal and acoustic performance, fire resistance and cost of the raw material (soil). In fact, earth construction can constitute a feasible solution for a more sustainable construction industry in developed countries. Nowadays the research areas on earthen construction focus from one side on the improvement of the materials for new buildings, on the other side on the Conservation of existing architectural heritage.
Historical earthen buildings are often damaged by static or dynamic loads in form of extensive cracking. All too often these cracks are insufficiently or inappropriately repaired, if at all, because of lack of knowledge and/or technology. In particular, the behaviour of crack repair by grouting poses a challenge in earthen materials and demands specific requirements for the grouting mortar, such as low water content, good water retention, low shrinkage, etc. Cracks in earthen construction can be repaired by grouting to re-establish structural continuity, and can also be used to consolidate voids and gaps, or as a complement to other strengthening techniques such as the introduction of tie-rods.
In the framework of earthen materials for new constructions, the major drawback is that traditional earthen materials are typically considered as non-standard. The great variability and heterogeneity of the properties of the available soils, the lack of quality control in the manufacturing of the earthen materials and in the construction process can be pointed out as the main reasons behind this Situation. Furthermore, only few countries issued Standards and recommendations supporting earth construction, discouraging the design of earth construction by the technical community in countries where these documents are absent.
In this paper we present results of our recent efforts to understand the mechanical interface behaviour of single-walled carbon nanotubes (CNTs) embedded in metal matrices. We conducted experimental pull-out tests of CNTs embedded in Pd or Au and found Maximum forces in the range 10 - 102 nN. These values are in good agreement with forces obtained from molecular Dynamics simulations taking into account surface functional Groups (SFGs) covalently linked to the CNT material. The dominant failure mode in experiment is a CNT rupture, which can be explained with the presence of SFGs. To qualify the existence of SFGs on our used CNT material, we pursue investigations by means of fluorescence labeling of surface species in combination with Raman imaging. We also report of a tensile test system to perform pull-out tests inside a transmission electron microscope to obtain in situ images of CNT-metal interfaces under mechanical loads at the atomic scale.
Build-up strategies for generating components of cylindrical shape with laser metal deposition
(2015)
Laser Metal Deposition LMD) as additive manufacturing process offers the potential to produce near net shape components. This reduces the amount of material and post-processing. The components are composed of individual layers. Already mall irregularities within a layer can add up over multiple layers and lead to error propagation. This paper deals with the issue of build-up strategies to minimize irregularities and prevent error propagation. Different travel paths and the influence of a changing starting point regarding to error propagation are discussed. Different deposition rates between core and peripheral area are detected and successfully compensated by adjusting the build-up sequence. Stainless steel and titanium alloy Ti-6Al-4V are used in the experiments. The results are intended to illustrate the potential of an adjusted build-up strategy and provide basic information on the way to an automated deposition process. This paper is of interest for engineers in industry or science using LMD as additive manufacturing process.
The damage process of short glass fibre (30% weight) reinforced polyamide caused by mechanical loading was investigated from the beginning on micro cracking level to the incipient crack of mm-dimension. Based on high resolution computer tomography and the X-ray-refraction technique the inner surface due to micro-cracking at the short fibre ends and the fibre matrix debonding of the skin surface of the filament was determined quantitatively. With the knowledge of the fatigue crack propagation rate and fracture toughness of the material from former research projects, it was derived that the total inner surface due to micro cracks measured by X-ray refraction is much higher than the specimen could have withstand the load, supposed the surface is in a localized crack. Hence, the damage process could be described from micro to macro level. Accompanying fractographic investigations endorse the modelling based on the NDT-techniques.
Das Laser-MSG-Hybridschweißverfahren führt bei untersuchten hochfesten Pipelinestählen API X80 und X120 reproduzierbar zu Schweißverbindungen mit anforderungsgerechten Zähigkeitseigenschaften.
Eine metallurgische Beeinflussung der Schweißnahtzähigkeit ist durch eine gezielte Auswahl des Zusatzwerkstoffes möglich, wobei die maximale Eindringtiefe des Zusatzwerkstoffes in die Tiefe der Laserhybridnaht zu beachten ist.
Die maximal erzielbare Eindringtiefe des Zusatzwerkstoffes ist auf ca. 14 mm begrenzt. Die eingesetzte Art des MSG-Lichtbogens hatte keinen erkennbaren Einfluss auf die Aufmischung im Laseranteil der Laserhybridnaht.
Die besseren Ergebnisse der Kerbschlagzähigkeit konnten mit Metallpulverdrähten erreicht werden.
Mit den erzielten gemittelten Werten der Schlagarbeit: ca. 200 J bei -60°C für X80 und ca. 53 J bei -40°C für X120 werden Anforderungen der Norm API 5L und DIN EN 10208-2 für die beiden untersuchten Grundwerkstoffe erfüllt.
Structuring of LTCC substrates by a combination of pressure-assisted sintering and hot-embossing
(2015)
A novel technology for the structuring of LTCC surfaces is introduced. The material is shaped in a zero-shrinkage process by embossing a glassy carbon mold into the softened LTCC directly after termination of the shrinkage. Three commercially available LTCC compositions (Ceramtape GC, Heratape CT707, and DP951) were tested. Diverse raised and lowered structures including rings, grids, and characters were fabricated. Different material behavior was observed for the tested compositions. Promising results were achieved with Ceramtape GC. Embossing of precise, 40 µm deep circular cavities and 50 µm high raised characters is demonstrated. Processing of 100 × 100 mm² substrates is possible. DP951 showed very good moldability, but also unwanted material displacement due to evaporating lead. A high displacement capacity but uneven heights of embossed structures were observed on CT707 samples. SEM investigations proved the precise transfer of surface contours from the mold to the LTCC. Thereby, the high potential of the hot-embossing process for micro-patterning of LTCC is illustrated.
The knowledge of dissolution processes of aggregates and supplementary cementing materials (SCMs) in alkaline solutions can help to describe the expansion of concretes caused by alkali-silica reaction (ASR) and the effects to avoid ASR by using SCMs in more details. Therefore, dissolution experiments in alkaline solutions under different pH values and different temperatures were performed using aggregates in the original grain size and SCMs in different ratios. The concentrations of soluble silica and additionally alumina were determined by ICP-OES. The investigations showed that up to now the “best” conditions to explain the damage behavior of concrete structures are a pH value of 13 (e.g. 0.1 M KOH solution) and a temperature of 80 °C. The evaluation bases on the parameter “excess silica” which is calculated from the dissolved silica and alumina of the aggregates and the SCMs. It was demonstrated that SCMs reduce and sometimes stop the dissolution of aggregates. The efficiency of the SCMs depends on their amount and chemical composition.
The use of supplementary cementing materials (SCMs) added to concrete mixtures can avoid the alkali-silica reaction. Such materials have a wide range of composition and therefore the inhibition mechanisms can be very differently.
The effectiveness of SCMs which provide silica and alumina into the alkaline solution cannot only be explained by reducing the OH--concentration of the pore solution. From dissolution experiments in potassium hydroxide solutions, an interaction was noted between the aggregate and five SCMs via the alkaline solution. Under specific conditions, no silica is released from the aggregate grains.
Mineralogical investigations (XRD, SEM+EDX) of the grain surfaces confirm that quartz is the main source of silica. In the presence of alumina providing SCMs, the quartz dissolution is strongly reduced or even sometimes stopped. On surfaces of grains a very thin layer can be observed which is probably responsible for reduction or stopping of the silica dissolution and therefore for the inhibition of ASR.
In order to estimating the amount and kind of emissions from polymeric sporting tracks a laboratory test was developed in BAM that combines artificial weathering and subsequent batch and column tests [1, 2, 3]. The goal consisted in nvestigating a possible change of emissions into soil and groundwater of a new sporting ground as a function of ageing and egradation of the system. At various stages of the weathering, the samples were removed and subjected to especially designed column extraction tests for the solid samples. Both these extracts and the accumulated rainwater run-off of the weathering device were subjected to analytical tests of their ingredients. The overall aim of the test consisted in developing ontrollable, reproducible, and standardisable conditions and methods of investigation that would allow an estimation of the emissions in the course of outdoor application of about five years.
The stress vs. strain curve of materials is affected the rate of imposed straining. Among the methods for dynamic testing the technique known as 'split Hopkinson pressure bar' (SHPB) has evolved into the most widely used one to exert high-speed straining. The theory behind it comprises simple equations to compute stress and strain. The reliability of the strain analysis can be assessed by digital image correlation (DIC). The present results indicate that the visually observed strain is smaller than predicted by theory.
Full penetration high power bead-on-plate laser beam welding tests of up to 20 mm thick 2205 duplex steel plates were performed in PA position. A contactless inductive electromagnetic (EM) weld pool support system was used to prevent gravity drop-out of the melt. Welding experiments with 15 mm thick plates were carried out using IPG fiber laser YLR 20000 and Yb:YAG thin disk laser TruDisk 16002. The laser power needed to achieve a full penetration was found to be 10.9 and 8.56kW for welding velocity of 1.0 and 0.5 m min(-1), respectively. Reference welds without weld pool support demonstrate excessive root sag. The optimal value of the alternating current (AC) power needed to completely compensate the sagging on the root side was found to be approximate to 1.6 kW for both values of the welding velocity. The same EM weld pool support system was used in welding tests with 20 mm thick plates. The laser beam power (TRUMPF Yb:YAG thin disk laser TruDisk 16002) needed to reach a full penetration for 0.5 m min(-1) was found to be 13.9 kW. Full penetration welding without EM weld pool support is not possible-the surface tension cannot stop the gravity drop-out of the melt. The AC power needed to completely compensate the gravity was found to be 2 kW. (C) 2016 Laser Institute of America
An electromagnetic weld pool support system for 20 mm thick duplex stainless steel AISI 2205 was investigated numerically and compared to experiments. In our former publications, it was shown how an AC magnetic field below the process zone directed perpendicular to the welding direction can induce vertically directed Lorentz forces. These can counteract the gravitational forces and allow for a suppression of material drop-out for austenitic stainless steels and aluminum alloys. In this investigation, we additionally adopted a steady-state complex magnetic permeability model for the consideration of the magnetic hysteresis behavior due to the ferritic characteristics of the material. The model was calibrated against the Jiles-Atherton model. The material model was also successfully tested against an experimental configuration before welding with a 30 mm diameter cylinder of austenitic stainless steel surrounded by duplex stainless steel. Thereby, the effects of the Curie temperature on the magnetic characteristics in the vicinity of the later welding zone were simulated. The welding process was modelled with a 3D turbulent steady-state model including heat transfer and fluid dynamics as well as the electromagnetic field equations. Main physical effects, the thermo-capillary (Marangoni) convection at the weld pool boundaries, the natural convection due to gravity as well as latent heat of solid–liquid phase transitions at the phase boundaries were accounted for in the model. The feedback of the electromagnetic forces on the weld pool was described in terms of the electromagneticinduced pressure. The FE software COMSOL Multiphysics 4.2 was used in this investigation. It is shown that the gravity drop-out associated with the welding of 20 mm thick duplex stainless steel plates due to the hydrostatic pressure can be prevented by the application of AC magnetic fields between around 70 mT and 90 mT. The corresponding oscillation frequencies were between 1 kHz and 10 kHz and the electromagnetic AC powers were between 1 kW and 2.3 kW. In the experiments, values of the electromagnetic AC power between 1.6 kW and 2.4 kW at oscillation frequencies between 1.2 kHz and 2.5 kHz were found to be optimal to avoid melt sagging or drop-out of melt in single pass fullpenetration laser beam welding of 15 mm and 20 mm thick AISI 2205.
For the design of laminates the knowledge of the failure behaviour of plies under multiaxial stresses is a necessary precondition. The strength of plies under multiaxial stresses commonly is determined by standard off-axis tests using fixed clamps. By varying the off axis angle the ratio of shear to normal stresses can be prescribed. However, by preventing the rotation a complex stress field develops which strongly varies with the off axis angle as well. While these effects are not crucial when determining the elastic material parameters since the stress state in the center of the specimen is not far from the ideal uniaxial stress state they have a great influence on the failure behaviour.
The new standard ‘ISO 17636-2:2013: Non-destructive testing of welds — Radiographic testing — Part 2: X- and gamma-ray techniques with digital detectors’, defines the practice for radiographic inspection of welded pipes for manufacturing and in-service inspection. It is applied in Europe for inspections of pipe welds in nuclear power plants as well as in chemical plants and allows a faster inspection with digital detector arrays (DDA) than with film. Nevertheless, it does not allow the evaluation of the depth and shape of volumetric and planar indications. In 2001 a planar tomography scanner, TomoCAR, was introduced for mechanized radiographic testing (RT) inspection and non-destructive measurement of cross sections. The project TomoWELD is based on a new concept of the scan geometry, an enhanced GPU based reconstruction, and the application of a new generation of photon counting DDAs based on CdTe crystal CMOS hybrids. The new detector permits the selection of energy thresholds to obtain an optimum energy range and reduction of the influence of scattered radiation. The concept and first measurements are presented. Flaw depth and shape of volumetric and planar irregularities can be determined.
The numerical simulations of high power laser keyhole welding at different welding positions are performed by using Volume-Of-Fluid (VOF) method. The main material is SS400. The multi-physics phenomenon is considered using several models, such as the heat flux of Gaussian heat source, the recoil pressure with Clausisus-Clapeyron equation, the Marangoni flow considering temperature gradient, the buoyancy force with Boussinesq approximation, the additional shear stress and heat source due to metallic vapor ejected through keyhole entrance, the bubble formation assumed as adiabatic bubble, and the multiple-reflection by solving proper discriminant, are used. To analyze the fluid flow pattern, the concept of streamline formed by reconstructing the value of the velocity vector is applied.
Partial and full penetration cases at different welding positions are considered. The welding position seems to have only a minor influence on bead formation characteristics in both cases. This is probably due to the fact that the recoil pressure has a major influence when compared to other driving forces. The flow characteristics and fluid velocity in weld pool are analyzed to compare the gravity direction effect at different welding positions. It is observed that the clockwise flow pattern is mainly formed by the recoil pressure on the keyhole surface in the case of partial penetration. The laser energy can't maintain the whole weld pool when the weld pool size becomes too large. And then the solidification starts from the middle part of weld pool and a necked weld pool shape is formed. In the full penetration welding, the weld pool flow patterns are affected by the leakage of laser power through the full penetration keyhole and also by surface tension. Furthermore, the numerical simulation of full penetration welding with AISI316L is also performed to analyze the effect of material properties. The weld bead shapes obtained by simulations were compared with the corresponding experimental results to confirm the validity of the process models adopted and the CFD simulation tool.
Experimental study and numerical simulation of hot crack formation for novel laser weldability test.
(2015)
Laser beam welding is a widely established manufacturing process in several industries. The solidification cracking seriously effecting the safety of welded joints could arise during the beam welding of stainless steels caused by high solidification rates. In this study the controlled tensile weldability test (CTW) was used to investigate the solidification cracking susceptibility the fully austenitic stainless steels CrMnNi (1.4376), CrNi (1.4301), CrNiMo (1.4404) and CrNiSi (1.4828) during laser beam welding. The test facility allows welding of specimens with simultaneous application of tensile load along or cross to the welding direction while the speed of tensile force application is either constant or increases linearly. The tensile force increment and/or the displacement are set by means of a CNC controller. Trials were conducted by varying the ultimate tensile strain and cross-head speed while keeping the welding parameters constant. By observing the crack-no crack behaviour and estimating the generated crack length for each trail using a new optimized experimental procedure the influence of the two important conditions (the strain and the strain rate) for the formation of solidification cracks can be investigated, the critical values of strain and strain rate that are responsible for solidification cracking formation have been determined. In the present study a three-dimensional FEM using the contact element technique was developed to simulate the solidification cracking during laser full penetration welding under external load conditions for the steel 1.4376 in order to get a better understanding of the mechanisms of hot crack initiation and the theoretical results were compared to the experimental ones. By comparing the resulting solidification crack with simulated crack, it is possible to determine the critical condition of solidification crack formation in the region where the strains and the strain rates cannot be measured due to the high temperature. The results show a good agreement between numerical calculation and experiment. It is proposed that the solidification cracking susceptibility may be predicted by FEM analysis by using the correct mechanical and thermo-physical constants of the materials.
The influence of temperature and counterbody material on the tribological properties of a-C:H
coatings deposited on Cronidur 30 steel has been investigated in a lubricated ball on disk
contact situation with alpha-alumina and silicon nitride as counterbodies. The results show, that the wear volumes of the systems increase exponentially with increasing temperature, for alpha-alumina more than for silicon nitride. Two different wear mechanisms seem to have a
major influence: First, the abrasive action due to materials hardness and second, the tribo-oxidation when silicon nitride is counter material.
In the past few years, the share of earthen building materials used in constructions in Central Europe has increased. That is due to growing acknowledgement of its qualities regarding balancing of humidity, absorption of odours and acoustical insulation.
To regulate these (mostly indoor) uses, the German Institute for Standardization (DIN) has published norms for adobe, earth mortar for masonry and earth plaster. In addition to these traditional building materials, earthen panels have been developed. As an ecological alternative to gypsum plaster boards, they combine climatic advantages of traditional materials with economic advantages of industrial processing, i.e. prefabrication and drywall techniques. Earthen panels are a composite layered material, comparable to Textile Reinforced Concrete (TRC). Most products contain an inner layer of reed tubes which improve the tensile strength and reduce the weight. Often, one or both surfaces are reinforced with a fibrous net to prevent cracks in the plastering that is usually applied on top. Additives range from straw to expanded clay. Special panels contain waxes that improve their heat storage capacity or water pipes to allow the usage as flat heating and cooling systems.
CONRAD-2 is an imaging instrument using low-energy (cold) neutrons. The instrument is installed at the end of a curved neutron guide which avoids the direct line of sight towards the reactor core. This ensures a very low background of high-energy neutrons and. photons at the sample position. The cold neutron beam provides a wavelength range which is suitable for phase-and diffraction-contrast imaging such as grating interferometry and Bragg edge mapping. The instrument is well suited for high resolution imaging due to the high efficiency of the very thin scintillators that can be used for the detection of cold neutrons. An instrument upgrade was performed recently as a part of an upgrade program for the cold neutron instrumentation at HZB. The parameters of the instrument as well as some research highlights will be presented.
Laser welding is a widely established manufacturing process in many industry sectors. Solidification cracking represents one of the most inadequately solved problems in welding and has major economic implications. The avoidance of hot crack forms for most fusion welding processes poses a key challenge for an important range of metallic construction materials and affects not only the manufacturers of welding equipment and material manufacturers, but also a large number of customers using welding technologies, as well as welding technical standardization and research. Solidification cracking susceptibility was examined with the help of the Controlled Tensile Weldability Test (CTW) developed by Federal Institute for Materials Research and Testing (BAM), Berlin. The test is based on the fact that hot crack formation depends on a critical strain that emerges within a critical temperature range, the so called brittle temperature range (BTR). Using this test and defined investigation programme a centreline solidification crack was generated. By controlling the applied strain during the laser beam welding process, it was possible to determine the critical strain and strain rate that led to solidification cracking formation. The hot cracking susceptibility of the tested stainless steels was qualified and quantified. The results demonstrate that the crack length increases with increasing applied strain. Furthermore, the strain rate has a significant influence on the formation of the solidification crack.
Laser welding is a widely established manufacturing process in many industry sectors. Solidification cracking represents one of the most inadequately solved problems in welding and has major economic implications. The avoidance of hot crack is for most fusion welding processes a key challenge for an important range of metallic construction materials and affects not only the manufacturers of welding equipment and material manufacturers, but also a large number of customers using welding technologies, as well as welding standardization and research. In this study a new investigation programme has been developed to qualify the hot cracking susceptibility of a variety of austenitic stainless steels. The results show the possibility of using this technique to determinate the critical values that occur with initiation of solidification cracking during laser beam welding
The plastic deformation results in irreversible microstructure changes in the steel, which can be considered as the initial stage of the fracture process. However, detecting, monitoring and evaluating, damage states and small defects non-destructively in advance still proves challenging. Dubov reported the phenomenon of the spontaneous emergence of weak magnetic fields in ferritic structural steel and pipelines, which originate due to heterogeneous mechanical and / or thermal stresses. This observation is not associated with induced phase transformations by deformation and appears to be a promising tool for the prior characterization of damage in ferromagnetic steels. To provide a better understanding of the physical bases of the process, the magnetic microstructure of such materials and a change of magnetic domains after undergoing plastic deformation were studied. A colloidal solution with paramagnetic particles in the nanometer range (ferrofluid), which allowed, through the Bitter technique, not only to observe a change in size of the magnetic domains of the material, but also changes in their morphology. Ferritic steels with their concentrations of carbon in its composition (0.12%; 0.17% and 0.45%) were studied in this work.
This contribution will show that gel-type electrolytes influence protective layers on zinc coatings considerably less than typical bulk electrolytes. Different zinc coatings are investigated, their naturally formed protective layers are electrochemically characterized and corrosion relevant values are determined by using a gel pad based on polysaccharide. From the results it is evident that gel-type electrolytes represent a viable and promising field in corrosion research.
This work presents the use of limited experimental measurements to develop a set of calibrated Simulation parameters that can then be used for reliable simulation of subsea pipeline inspections. The modelling software aRTist is used as the simulation tool, and the calibration is through comparison with experimental images of a well characterised sample in a water tank. Image Quality parameters such as signal-to-noise ratio, contrast and basic spatial resolution are compared with the aim of matching simulated values to experimental results. Currently the model is partially calibrated, with signal-to-noise ratio successfully matched while differences are still found in contrast-to-noise ratio comparisons. This means that measurements depending on absolute intensity are not accurate enough in the simulation at this stage. However, the simulation is found to be accurate for wall thickness measurements in tangential images, which are not based on absolute intensity, with simulated and experimental cases producing similar results.
Accurate and reliable detection of subsea Pipeline corrosion is required in order to verify the integrity of the pipeline. A laboratory trial was conducted with a representative pipe sample. The accurate measurement of the wall thickness and corrosion was performed with high energy X-rays and a digital detector array. A 7.5 MV betatron was used to penetrate a stepped pipe and a welded test pipe of 3 m length and 327 mm outer diameter, with different artificial corrosion areas in the 24 mm thick steel wall. The radiographs were taken with a 40 x 40 cm² digital detector array, which was not large enough to cover the complete pipe diameter after magnification. A C-arm based geometry was tested to evaluate the potential for automated inspection in field. The primary goal was the accurate measurement of wall thickness conforming to the standard. The same geometry was used to explore the ability of a C-arm based scanner in asymmetric mode for computed tomography (CT) measurement, taking projections covering only two thirds of the pipe diameter. The technique was optimized with the modelling Software aRTist. A full volume of the pipe was reconstructed and the CT data set was used for reverse engineering, providing a CAD file for further aRTist simulations to explore the technique for subsea inspections.
Analyzing the reliability of non-destructive tests using the modular modell - a practical approach
(2016)
Non-destructive testing is an important tool to guarantee the safety of railway traffic.
The infrastructure with tracks, switches and sleepers is regularly tested, the
locomotives and wagons with their wheels, bogies and axles as well. Many years of experience and some events lead in Germany to a good practice in testing the railway components. Now, European authorities are drafting a system of common requirements and standards for the European Railway Market. The German practice combines an intensive training of the NDT-personnel including sufficient time for practical exercises with organizational measures of the companies, responsible for rolling stock and infrastructure. Through the example of UT-testing of railway axles it will be shown, how training and organizational measures influence the reliability of such testing.
The usefulness and purpose of evaluating nondestructive testing (NDT) systems and their capabilities has changed in the last decade. The conventional method of simply applying a familiar statistical algorithm to say whether the system is usable for the tasks is history.
Nowadays, multiple parameter methods which describe the probabilities of detection (POD) of different systems or real defects need new characteristics and a broader variety of statistical models to describe the true system behaviour. The appraisal of the NDT system involves diverse departments within a company (engineering, NDT-operators, and statisticians), but is, at the same time, more needed and requested than in the past. In this article, an approach is discussed in which professionals from different fields worked well together, accomplishing cost-intensive metallographic studies in correlation with well-understood physical behaviour of NDT-methods as well as deep-discussed mathematical methods to create a holistic evaluation of the technical reliability for a specific radiographic testing (RT) equipment. The first part of the publication will show the comparison between metallographic grinding and the RT indications. An essential innovation over past evaluation methods was the use of a multi-scale smoothing algorithm, which describes physical parameters, which were not used in evaluation like the POD in this way in the past.
In the second part the statistical requirements for the POD take the focus. It can often be hard to make significant statements; especially in the case where only a small amount of data is available. The combination of data and the use of knowledge from simulations are essential. One possible solution will be shown for the RT evaluation. The methodology is used for evaluating the digital RT system for the inspection of electron-beam welds, which was method considered to seal the Finnish copper canisters for the final deposit of spent nuclear fuel.
Ultrasonic phased array is, currently, the technology which is being applied as the solution to a lot of inspection problems. The perceived benefits are seen to be worth the outlay on equipment and specialised personnel. Yet, there is a source of knowledge, freely available, which can also deliver immediate benefits, through more reliable inspection results, and consequently increased client confidence, but which is largely ignored by the greater part of the NDT community. This talk will review the latest Human Factors knowledge and provide practical illustrations of how companies can use it to improve their competitive edge.
The General Guidance in the Swedish regulations state that the safety assessment for a final repository for spent nuclear fuel should be 1 million years after closure. SKB developed the KBS-3 method, according to which the spent nuclear fuel is protected by three barriers. It is encapsulated in canisters with a diameter of 1 metre and a length of 5 metres. The canister consists of a cast iron insert surrounded by a 5 centimetre thick shell of copper. The canisters are disposed in the bedrock at a depth of about 500 meters surrounded by bentonite clay. In order to assess the safety over this extremely long period, an extensive quality control programme is applied to the canisters before deposit. In this programme, the use of
non-destructive testing (NDT) is vital. The safety assessment of the canister in turn places high demands on the coverage, detectability, and reliability of the applied NDT inspections of the canister parts, i.e. cast iron insert, copper base, tube and lid, and the copper friction stir welds (FSW). This paper presents the extensive full-scale inspection development programme that runs at the Canister Laboratory in Oskarshamn (Sweden). In order to fulfil the high demands, phased array ultrasonic inspection techniques are developed using practical trials aided by ultrasonic modelling. The techniques apply, for example, different frequencies, inspection angles, focus depths, and both longitudinal and shear waves. Increased inspection reliability of the FSW is achieved by applying digital X-ray technique using a 9 MeV linear accelerator and a line detector. To complete the coverage, complementary surface inspections methods, i.e. eddy current array, magnetic flux sensor techniques and magnetic particle inspection, are applied. The canister safety assessment was the driving force to include reliability studies during the NDT development. Initially, the technical reliability was considered, resulting in development of advanced POD models (probability of detection). In combination with human factors studies, these models were implemented as tools in the development of the NDT techniques. Human factors studies were also applied to improve the inspection procedures to be more user-friendly enabling reliable inspections.
Currently at Deutsche Bahn (DB) ultrasonic inspections in maintenance procedures for wheelset axles with a bore hole are, to the greatest possible extent, carried out using automated ultrasonic inspection system. Although the acceptance levels are in accordance with DIN 27201 part 7, the testing results have shown in recent years that in the case of true indications, the effective defect sizes were far below the level of acceptance. Due to this experience it can be assumed that the automated ultrasonic inspection systems are testing substantially more sensitively than required. This increased sensitivity leads to an increase in false indications, generally resulting in the unnecessary demounting of wheelsets. In Research cooperation between Federal Institute for Materials Research and Testing (BAM) and DB the effective flaw detection sensitivity of existing automated ultrasonic inspection system will be determined and the true/false indication ratio optimised. Through systematic investigations with the Probability of Detection method on the existing automated ultrasonic inspection system the results could be directly applied to the optimisation of existing ultrasonic inspections of wheelset axles with a bore hole in maintenance procedures and the level of reliability can be considerably increased.
The multiple-sample approach by means of centrifugal adhesion testing (CAT-technology) allows the determination of bonding strength of adhesive-bonded joints on a statistical basis of up to eight samples. Therefore, it is obvious to ensure the continuous handling and identical processing of an octet of samples within the entire process chain of wet-chemical cleaning, plasma-chemical pre-treatment, bonding of samples, and testing of bonding strength. Within the multiple-sample bonding set-up (MPKV-technology) a defined bonding pressure can be adjusted regardless the actual number of samples. A comparison of single- and multiple-sample approach is made for bonding strength of selected adhesives, double-sided adhesive tapes and different material combinations [stainless steel (V2A) vs. stainless steel, polyamide (PA), or polypropylene (PP)]. It is shown that both technologies improve reliability of results
The future commercial prospects for adhesive tapes are very good and its application range is very broad. From every-day-use in office, packaging, maintenance, and quick repair in workshops, it ranges from handicraft work, medical purposes and cosmetics up to workmanship. The study describes a new multi-sample approach in adhesive tape testing from theoretical background, preparation of test specimen for tensile as well as shear testing, detailed measurement procedures up to analysis and result interpretation. Various types of single and double-sided pressure sensitive adhesive tapes supplied by different manufacturers were investigated and compared
High-power laser beam welding became new stimuli within the last 10 years due to the availability of a new generation of high brightness multi kilowatt solid state lasers. In the welding research new approaches have been developed to establish reliable and praxis oriented welding processes meeting the demands of modern industrial applications during this time. The paper focuses on some of the current scientific and technological aspects in this research field like hybrid laser arc welding, simulation techniques, utilization of electromagnetic fields or reduced pressure environment for laser beam welding processes, which contributed to the further development of this technology or will play a crucial role in its further industrial implementation.
Der Einsatz von nichtrostenden Duplexstählen im Bauwesen findet in den letzten Jahren zu-nehmende Verbreitung. Insbesondere die Lean-Duplexstähle sind aufgrund geringerer not-wendiger Legierungszuschläge von Nickel und Molybdän eine kostengünstigere Alternative zu den jahrzehntelang etablierten austenitischen Stahlsorten. Verschiedene Korrosionsuntersu-chungen an der BAM sowie Erfahrungen aus der Anwendung konnten nachweisen, dass Lean-Duplexstähle unter verschiedenen Einsatzbedingungen ein vergleichbar gutes, in man-chen Fällen sogar besseres Korrosionsverhalten aufweisen als austenitische Referenzwerkstoffe der gleichen Korrosionswiderstandsklasse. Im Hinblick auf die technisch-mechanischen Eigenschaften konnten von der Fa. Modersohn initiierte Untersuchungen zeigen, dass unter Beachtung der gefügebedingten Einsatzgrenzen eine gute Verarbeitbarkeit und mechanische Sicherheit bei gleichzeitiger Materialeinsparung gewährleistet werden kann. Die positiven Ver-suchsergebnisse haben wesentlich zur Akzeptanz und einer damit einhergehenden Erweiterung der Einsatzgebiete dieser alternativen Werkstoffe im Bauwesen beigetragen.
Metal additive manufacturing is often based on laser beam processes like Laser Metal Fusion (LMF) or Laser Metal Deposition (LMD). The LMF process is in particular suitable for very complex geometries. However build rate, part volume and material flexibility are limited in LMF. In contrast, LMD achieves higher deposition rates, less restricted part sizes and the possibility to change the material composition during the build-up process. On the other hand, due to the lower spatial precision of the material deposition process, the complexity of geometries is limited. Therefore, combined manufacturing with both LMF and LMD has the potential to utilize the respective advantages of both technologies.
In this paper, combined additive manufacturing with LMF and LMD is described for Ti-6Al-4V and Inconel 718. First, lattice structures with different wall thickness and void sizes are built with LMF. The influence of LMD material deposition on these LMF-structures is examined regarding metallurgical impact and distortion. Cross-sections, x-ray computer tomography and 3D-scanning results are shown.
For the titanium alloy specimen, oxygen and Nitrogen content in the deposited material are analysed to evaluate the LMD shielding gas atmosphere. The results are used to develop guidelines for a LMD build-up strategy on LMF substrates. With these findings, a gas turbine burner is manufactured as reality test for the combined approach.
BAM is the federal institute for materials research and testing in Germany. One of our tasks is to evaluate the safety of casks designed for transport and/or storage of radioactive waste. As elastomeric seals are used in the containers as safety-relevant parts, it is our goal to be able to evaluate the service lifetime of the seals with regard to the requirements for long-term safety (40 years and more) of the containers. For this reason, an accelerated ageing programme with selected rubbers often used for seals (HNBR, EPDM and FKM) was started. Ageing was performed at four different temperatures (75 °C, 100 °C, 125 °C and 150 °C) for up to 2 years. For assessing properties related to the sealability, O-rings were aged in compression by 25 % (corresponding to the compression during service) between plates. For comparison, uncompressed O-rings were aged as well. The aged materials were characterized with conventional polymer analysis methods such as hardness and tensile tests, but also with more seal-specific methods such as compression stress relaxation (CSR, reflecting the loss of sealing force of a compressed seal over time), and compression set (CS, representing the recovery behaviour of a seal after release from compression). CS is chosen as the property for lifetime prediction as it is both sensitive to degradation and related to the seal performance. CS data is extrapolated to 60 °C, which yields lifetimes of approximately 5 years for HNBR and 64 years for EPDM for a criterion of 85 % CS respectively, and approx. 40 years for FKM for a criterion of 65 % CS (the highest value measured so far).