Ingenieurwissenschaften und zugeordnete Tätigkeiten
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Eingeladener Vortrag
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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.
Rubber is widely used as sealing material in various applications. In many fields the function of seal materials at low temperatures is necessary. Therefore, the understanding of failure mechanisms that lead to leakage at low temperatures is of high importance.
It is known that the material properties of rubbers are strongly temperature dependent. At low temperatures this is caused by the rubber-glass transition (abbr. glass transition). During continuous cooling, due to the glass transition the material changes from rubber-like entropy-elastic behaviour to stiff energy-elastic behaviour, that allows nearly no strain or retraction. Hence, rubbers are normally used above their glass transition. But as the minimum working temperature limit of elastomers cannot be defined globally and precisely, the lower operation temperature limit of rubber seals should be determined in dependence of the application conditions and the most relevant material properties.
In this paper, wesummarize results of our temperature dependent investigation of seal material properties by classical thermal analysis as Differential Scanning Calorimetry (DSC) and Dynamic Mechanical Analysis (DMA), combined with measurements of standardized tests as compression set and the seal performance determined in component tests. To reduce the test time of compression set tests a faster technique was developed and applied.
To study the influence of dynamic events on the seal performance and to enhance the understanding of occurring seal failure, a setup for a fast partial seal release was designed.
The steel grade 20MnMoNi5-5 (according to German DIN standard or 16MND5 according to French AFNOR standard) is widely applied in (weld) fabrication of reactor pressure vessel components. Thus, a wide range of welding technologies (like submerged arc welding (SAW) or tungsten inert gas (TIG)) is used resulting in different heat affected zone (HAZ) microstructures. During weld fabrication, the weld joints may take up hydrogen. Especially, the HAZ shows an increased susceptibility for a degradation of the mechanical properties in presence of hydrogen. In addition, the hydrogen-assisted degradation of mechanical properties is influenced by three main local factors: hydrogen concentration, microstructure, and load condition. Hence, the base material (BM) and two different simulated non-tempered as-quenched HAZ microstructures were examined using hydrogen-free and hydrogen-charged tensile specimens. The results indicate that the effect of hydrogen on the degradation is significantly increased in case of the HAZ compared to the BM. In addition, hydrogen has remarkable effect in terms of reduction of ductility. It was ascertained that the degradation of the mechanical properties increases in the order of BM, bainitic HAZ, and the martensitic HAZ. Scanning electron microscope (SEM) investigation showed a distinct change of the fracture topography depended on the microstructure with increasing hydrogen concentration in case of the as-quenched HAZ microstructures.
In this paper, we identify the strategic motives of German manufacturing companies in the electrical engineering and machinery industry to be involved in standards development organizations. First, we present the general motives for the formation of strategic alliances and relate them to specific standardization motives. Then, we identify pursuing specific company interests, solving technical problems, knowledge seeking, influencing regulation, and facilitating market access as motives to standardize by means of factor analysis. In a second step, we test hypotheses on the relationship between the importance of strategic motives and firm level variables, e.g. R&D intensity, innovation activities, and firm size. The results reveal that firms in electric engineering and machinery have a particularly strong interest in ensuring industry-friendly design of regulations, which can be achieved by standards. Moreover, the results confirm that small firms also from these two sectors are active in standardization alliances to access knowledge from other involved stakeholders.
Single wire Gas Metal Arc Welding (SGMAW) and high power Tandem GMAW (TGMAW) are evaluated with respect to energy efficiency. The key performance indicator Electrical Deposition Efficiency is applied to reflect the energy efficiency of GMAW in different material transfer modes. Additionally, the wall-plug efficiency of the equipment is determined in order to identify the overall energy consumption. The results show that energy efficiency as well as economic process performance can be significantly increased by application of tandem processes. A comparative Life Cycle Assessment of a 30 mm thick weld is conducted to investigate the influences of the energy efficiency on the environmental impacts. Environmental burdens in the categories Global Warming Potential, Acidification Potential, Eutrophication Potential and Photochemical Ozone Creation Potential can be reduced up to 11% using an energy efficient TGMAW process
Recent developments in Förster resonance energy transfer (FRET) diagnostics using quantum dots
(2016)
The exceptional photophysical properties and the nanometric dimensions of colloidal semiconductor quantum dots (QD) have strongly attracted the bioanalytical community over the last approximately 20 y. In particular, the integration of QDs in the analysis of biological components and interactions, and the related diagnostics using Förster resonance energy transfer (FRET), have allowed researchers to significantly improve and diversify fluorescence-based biosensing. In this TRENDS article, we review some recent developments in QD-FRET biosensing that have implemented this technology in electronic consumer products, multiplexed analysis, and detection without light excitation for diagnostic applications. In selected examples of smartphone-based imaging, single- and multistep FRET, steady-state and time-resolved spectroscopy, and bio/chemiluminescence detection of QDs used as both FRET donors and acceptors, we highlight the advantages of QD-based FRET biosensing for multiplexed and sensitive diagnostics.
Characterization of multiphase metal matrix composites by means of CT and neutron diffraction
(2016)
The present study examines the relationship between the microstructure of multiphase metal matrix composites and their damage mechanisms. The matrix AlSi12CuMgNi was combined with 15% vol. Al₂O₃ (short fibers), and with 7% vol. Al₂O₃ + 15% vol. SiC (short fibers and whiskers, respectively). The experimental approach encompasses 3D microstructure characterization by means of computed tomography of samples (a) as-cast, (b) after heat treatment, and (c) after compression tests at room temperature. The volume fraction of different phases, their distribution, their orientation, and the presence of defects and damage are studied.
The influence of the addition of SiC particles on mechanical properties of composite was investigated. Phase-specific load partition analysis for samples with fiber plane parallel to load was performed by using neutron diffraction (ND) during in-situ compression. ND results show damage in the Si phase, while Al₂O₃ short fibers carry load without damage until failure. The computed tomography observations confirm the load partition analysis.
Heat treated 9%Ni steel is considered the most suitable and economic material for construction of large-size liquefied natural gas (LNG) storage tanks which operate at cryogenic temperatures (-196°C). Strength above 700 MPa as well as a minimum impact value of 60 J are required to ensure reliable operation of the LNG tanks at operating temperature. Conventional arc welding processes, including shielded metal arc welding, gas metal arc welding, gas tungsten arc welding and submerged arc welding, are currently used in construction of LNG tanks. Ni based filler wire is the preferred filler metal of choice in LNG tank construction. The main problem with this choice is the lower mechanical properties, particularly tensile strength of the weld metal. To compensate, the wall thickness needs to be excessively thick to ensure the strength of the welded structures. Ni based filler material is expensive and a large quantity is needed to fill the multi-pass weld grooves. These factors significantly add to the cost in the fabrication of LNG storage tanks. For these reasons, exploration of new welding technologies is a priority. A big potential can be seen in laser based welding techniques. Laser beam welding results in much smaller fusion zone with chemical composition and mechanical properties similar to that of the base material. Laser welding is a much faster process and allows for a joint geometry which requires less filler material and fewer welding passes. The advantages of laser welding can help to overcome the problems pointed out above. Trials of autogenous laser welding, laser cold-wire welding and hybrid laser-arc welding conducted on the 9%Ni steel are presented in this paper. Chemical composition of the weld metal as well as effects of welding parameters on the weld formation, microstructure and tensile strength is discussed. Filler wire penetration depth as well as character of its distribution in the narrow laser welds was examined using EPMA - electron probe microanalysis.
Advanced methods for 3D green density characterization like computed tomography and 3D FE sinter modeling can be utilized for increasing the reliability of sintered components. The experimental in situ observation of sin-tering, however, is currently restricted to silhouette methods, i.e. heating microscopy. For complex shaped sam-ples, in situ shape screening during shrinkage would allow better validation of 3D sinter simulation models. Further, by revealing temporary sinter warpage, 3D high-temperature shape screening would allow to locate potential defects of complex sintered components. Against this background, BAM developed a testing device for in situ 3D high-temperature shape screening for ceramic and glass-ceramic tapes up to 1000°C [1-3]. Current work is focused on dropping this restriction in sample shape and temperature. The poster illustrates the current state of this work and possible applications of the method e.g. in detecting sinter warpage of metallized glass-ceramic LTCC tapes.
Nanoclays like laponites, which are commercially avaible in large quantities for a very moderate price, provide a facile solubilization strategy for hydrophobic dyes without the need for chemical functionalization and can act as a carrier for a high number of dye molecules. This does not require reactive dyes, amplifies fluorescence signals from individual emitters due to the high number of dyes molecules per laponite disk, and renders hydrophobic emitters applicable in aqueous environments. Aiming at the rational design of bright dye-loaded nanoclays as a new class of fluorescent reporters for bioanalysis and material sciences and the identification of dye structure−property relationships, we screened a series of commercial fluorescent dyes, differing in dye class, charge, and character of the optical transitions involved, and studied the changes of their optical properties caused by clay adsorption at different dye loading concentrations. Upon the basis of our dye loading density-dependent absorption and fluorescence measurements with S2105 and Lumogen F Yellow 083, we could identify two promising dye−nanoclay hybrid materials that reveal high fluorescence quantum yields of the nanoclay-adsorbed dyes of at least 0.20 and low dye self-quenching even at high dye-loading densities of up to 50 dye molecules per laponite platelet.