Ingenieurwissenschaften und zugeordnete Tätigkeiten
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Defect recognition in CFRP components using various NDT methods within a smart manufacturing process
(2018)
The manufacturing process of carbon fiber reinforced polymer (CFRP) components is gaining 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 process are e.g. porosity and voids which may lead to delaminations during operation and under load. To find irregularities and classify them as possible defects in an early stage of the manufacturing process is of high 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 compare various NDT methods which were applied to similar CFRP laminate samples in order to detect and characterize regions of 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 and evaluation of defects, we also investigate possibilities to combine various NDT methods within a smart manufacturing process in which the decision which method shall be applied is inherent within the process. 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 concepts 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.
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.
Ultrasonic guided waves interacting with complex geometrical features are of high interest in the SHM field. For example, investigations into the extent to which a small change in defect geometry affects wave propagation have applications in Probability of Detection and defect reconstruction. These fields have to be supported by numerical tools aiming to retrieve accurate and reliable results and, thus, more realistic modeling.
Due to the short wavelengths of ultrasonic waves and the relatively large domains in which the waves propagate, fine grid resolution for the entire domain is usually not possible due to limited computational resources. One solution is to partition the domain into different subdomains and use a specific, efficient approach for each subdomain.
This contribution shows a combination of methods that aims to study these wave defect interactions in an elastic media. Firstly we introduce high-order 3D meshes that can resolve very fine geometrical details and are based on an Octree discretisation technique that employs special transition shape functions to resolve the hanging nodes that may appear due to the nature of the method. Afterward, the Octree mesh is embedded in a prismatic wave-guide based on the semi-analytical formulation of the SBFEM in 3D. To couple the different domains, we employ the mortar method, which enforces the continuity of the wave field across the internal boundaries of the domains. Examples show the power of the approach especially when it comes to parametric analysis.
Integration of fiber reinforcement in high-performance cementitious materials has become widely applied in many fields of construction. One of the most investigated advantages of steel Fiber reinforced concrete (SFRC) is the deceleration of crack growth and hence its improved sustainability.
Additional benefits are associated with its structural properties, as fibers can significantly increase the ductility and the tensile strength of concrete. In some applications it is even possible to entirely replace the conventional reinforcement, leading to significant logistical and environmental benefits.
Fiber reinforcement can, however, have critical disadvantages and even hinder the Performance of concrete, since it can induce an anisotropic material behavior of the mixture if the fibers are not appropriately oriented. For a safe use of SFRC in the future, reliable non-destructive testing (NDT) methods need to be identified to assess the fibers’ orientation in hardened concrete. In this study,
ultrasonic material testing, electrical impedance testing, and X-ray computed tomography have been investigated for this purpose using specially produced samples with biased or random Fiber orientations. We demonstrate the capabilities of each of these NDT techniques for fiber orientation measurements and draw conclusions based on these results about the most promising areas for future research and development.
This paper presents a mode-tracing approach for elastic guided waves based on analytically computed derivatives and includes a study of interesting phenomena in the dispersion curve representation. Numerical simulation is done by means of the Scaled Boundary Finite Element Method (SBFEM). Two approaches are used to identify the characteristics of the resulting wave modes: Taylor approximation and Padé approximation. Higher order differentials of the underlying eigenvalue problem are the basis for these approaches. Remarkable phenomena in potentially critical frequency regions are identified and the tracing approach is adapted to these regions. Additionally, a stabilization of the solution process is suggested.
The influence of the atomization technique on the suitability of granules for dry pressing is the focus of the presented investigations. Therefore, destabilized alumina, zirconia, and zirconia toughened alumina (ZTA) slurries were spray dried and the obtained granules were used to fabricate green and finally sintered bodies for evaluation.
Granules made in a laboratory spray dryer with a two-fluid nozzle served as a reference. An ultrasonic atomizer was integrated into the same spray dryer and the influence on the granule properties was evaluated. Untapped bulk density, granule size distribution, and flowability are among the evaluated granule-related properties as well as the granule yield which is used as an indicator of the process efficiency.
Yield and flowability as most important granule properties are clearly improved when atomization is realized with ultrasound. The investigated sinter body properties include porosity, sinter body density, and biaxial strength and are as well positively affected by switching the atomization technique to ultrasound. Therefore, the Approach to improve the compressibility of granules by ultrasonic atomization, which leads to an improved microstructure, density, and strength of sintered bodies, has proven to be successful for single-component ceramics (alumina and zirconia) as well as for the multicomponent ceramic ZTA.
The homogeneous introduction of organic additives is a prerequisite for good processability of ceramic powders during dry pressing. The addition of organic additives by wet route via ceramic slurries offers advantages over dry processing. The organic content can be reduced and a more homogeneous distribution of the additives on the particle surface is achieved. In addition to the measurements of zeta potential and viscosity, sedimentation analysis by optical centrifugation was also tested and successfully used to characterize the ceramic slurries and accurately evaluate of the suitability of different types, amounts, and compositions of organic additives.
Spray drying of well-stabilized slurries usually results in mostly hollow granules with a hard shell leading to sintered bodies with defects and reduced strength and density. By purposefully degrading the slurry stability after dispersion of the ceramic powder, the drying behavior of the granules in the spray drying process and thus the granule properties can be influenced. Destabilization of the slurry and thus partial flocculation was quantified by optical centrifugation. Spray drying of the destabilized alumina slurries resulted in "non-hollow" granules without the detrimental hard shell and thus improved granule properties.
Further improvement of the granules was achieved by installing ultrasonic atomization in the spray dryer. A narrower granule size distribution was achieved, which had a positive effect on, among other things, the flowability of the granules.
Specimens produced from this granules had fewer defects of smaller size, leading to better results for the density and strength of the sintered bodies. The observations made for alumina could be transferred to zirconia and as well to ZTA with 20 wt% zirconia.
Dry pressing of ceramic materials requires homogeneously soft granules with good flowability to allow rapid die filling and to avoid packing defects. Spray-drying granulation appears to be the best method for obtaining granules with high flowability in industrial scale. But, strength reducing internal microstructural defects caused by spray-dried granules with hollow and hard shells are often observed using nano and/or multi-component starting powders.
Using the example of a ZTA composite, the potential of slurry optimization, ultrasound atomization and infrared drying for better granule properties and compaction behavior were investigated. Starting granules produced in a conventional spray dryer (Niro, Denmark) with a two fluid nozzle showed typical defects like large central pores and dimples.
The early step of slurry preparation already possesses an essential optimization possibility in the form of stability adjustments. Granule compaction was clearly improved upon a specific reduction in slurry stability. The second optimization opportunity to improve the granule quality was the atomization step. Implementation of an ultrasound atomizing unit into the conventional spray dryer positively affected granule size distribution and therefor flowability and as well granule yield. But, a combination of both process optimizations delivered the best sinter bodies with highest density and strength due to further reduction in maximum size and fraction of pores.
As last step of a spray drying process, the drying is the focus of further investigations. A current setup implying a spray dryer prototype utilizes stacked infrared heater in a countercurrent setup delivering a further increase in granule yield and enduring spraying process stability.
Homogeneous introduction of organic additives is a key of ceramic powder processing. Addition of organics to ceramic slurries holds advantages compared to dry processing like organic content reduction and a more homogeneous additive distribution on the particle surface.
Investigations of the alumina slurries were primarily based on zeta potential measurements and sedimentation analysis by optical centrifugation. Both methods were combined to determine a suitable additive type, amount and composition, whereas the spray drying suitability has been ensured by viscosity measurements. Granules, yielded by spray drying of such ideally dispersed alumina slurries, are mostly hollow and possess a hard shell. Those granules cannot easily be processed and can only hardly be destroyed in the following shaping step, leading to sinter bodies with many defects and poor strength and density.
The precise slurry destabilization, carried out after ideally dispersing the ceramic powder, shows a strong influence on the drying behavior of the granules and hence on the granule properties. A promising degree of destabilization and partial flocculation was quantified by optical centrifugation and resulted in improved granule properties. Spray drying the destabilized alumina slurries yielded homogeneous “non-hollow” granules without the above mentioned hard shell. Sample bodies produced of these granules exhibited a reduction of defect size and number, leading to better results for sinter body density and strength.
The positive effect of the slurry destabilization has been further improved, by exchanging the atomizing unit from a two-fluid one to an ultrasound atomizer with only minor slurry adjustments necessary. The controlled destabilization and ultrasound atomization of the ceramic slurry show excellent transferability for zirconia and even ZTA (zirconia toughened alumina) composite materials.
Advanced spray drying process by controlled slurry destabilization and ultrasonic atomization
(2017)
Spray drying of ceramic slurries aims for soft and free-flowing granules with homogenous microstructure suitable for uniaxial and isostatic pressing. A stable and continuous spray drying process of slurries with maximized solids content is a further development target, since a reduction of the energy intensive drying procedure is desirable.
First part of the investigation focuses on the development of an appropriate zirconia slurry for spray drying with optimized organic additive contents (dispersant + binder + pressing and lubricating agents). Characterization and improvement of slurries are based on zeta potential measurements and investigations of the sedimentation behavior in an optical centrifuge. Therefor the slurries were spray dried with a conventional spray dryer with a two stream nozzle run in fountain mode. The controlled destabilization of the slurries was introduced, since the unwanted formation of hard granules with donut-like shape could be circumvented. Spray drying of such modified slurries resulted in soft granules without voids and finally leaded to sintered bodies with improved microstructure, density and bending strength.
Expectedly, the destabilization process causes a significant increase in viscosity of the ceramic slurry. Hence, an alternative spraying concept utilizing an ultrasonic nozzle was tested. Indeed, the ultrasonic nozzle seems able to atomize slurries with viscosities beyond the capability of the regular two stream nozzles due to the slurry’s shear thinning behavior. In second part of the investigation the integration of the ultrasonic nozzle in a commercial spray dryer is shown and first results of the spraying tests are discussed. Continuous spraying processes of highly viscous alumina, zirconia and ZTA slurries were realized over an extended production period.