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At least 307 records · Page 17

Evaluating Acoustic Emission Signals as an in situ process monitoring technique for Selective Laser Melting (SLM)

In situ real-time monitoring of the Selective Laser Melting (SLM) process has significant implications for the AM community. The ability to adjust the SLM process parameters during a build (in real-time) can save time, money and eliminate expensive material waste. Having a feedback loop in the process would allow the system to potentially ‘fix’ problem regions before a next powder layer is added. In this study we have investigated acoustic emission (AE) phenomena generated during the SLM process, and evaluated the results in terms of a single process parameter, of an in situ process monitoring technique.

47 OTHER INSTRUMENTATION↗

Transformational faulting in Mn 2 GeO 4 from olivine to wadsleyite structure: Implications for physical mechanism of deep-focus earthquakes

High-pressure and temperature deformation experiments interfaced with acoustic emission (AE) monitoring have been conducted to study transformational faulting in Mn 2 GeO 4 olivine, which transforms to the β phase, isostructural to wadsleyite. Metastable Mn 2 GeO 4 olivine exhibits a marked embrittlement behavior at temperatures between 800 and 1100 K, emitting numerous AEs. At each temperature, brittle deformation is characterized by a two-stage process: (1) a “preparation” stage with numerous diffusedly located low-magnitude AEs and large b values (>2), and (2) a failure stage where larger-magnitude AEs form a planar distribution with b values about 1. Microstructure analysis reveals extensive kink band development in olivine grains in the recovered samples. Kink band boundaries (KBBs), with a typical thickness of ∼100 nm, are filled with a nanometric β-Mn 2 GeO 4 “gouge”. A dense array of secondary shear localizations is often present within the kink bands, suggesting significant shear deformation therein. The combined observations suggest that faulting in metastable Mn 2 GeO 4 olivine is a self-similar process, from grain-scale to the sample-scale. Both observed embrittlement behavior and the microstructure of metastable Mn 2 GeO 4 olivine are essentially identical to those in Mg 2 GeO 4 olivine we have reported previously, indicating that the physical mechanism of faulting in metastable olivine is insensitive to the specific crystallographic structure of the high-pressure phase. The low b values (about 1) observed in the faulting process in our experiments are similar to those of deep focus earthquakes in cold subduction zones. Our observed mechanism explains deep focus seismicity in cold metastable mantle wedges, provided that the self-similarity assumption holds to geological scales.

58 GEOSCIENCES↗

Analysis of Acoustic Emission Propagation in Metal-to-Metal Adhesively Bonded Joints

Acoustic emission (AE) monitoring shows promise as one of the most effective methods for condition monitoring of adhesively-bonded joints. Previous research has demonstrated its ability to detect, locate and classify adhesive joint failure, though in these studies little attention appears to have been paid to the differences in AE wave propagation through the bonded and un-bonded sections of the specimens tested, or to the effects of the wave modes excited or the propagation distances. This paper details an experimental study conducted on large aluminium sheet specimens to identify the effects of the presence of an adhesive layer on AE wave propagation. Three specimens are considered; a single aluminium sheet, two aluminium sheets placed together without adhesive, and an adhesively-bonded specimen. A pencil lead break (PLB) is used as a simulated AE source, and is applied to the three specimens at varying propagation distances and orientations. The acquired signals are processed using wavelet-transforms to explore time-frequency features, and compared with modified group-velocity curves based on the Rayleigh–Lamb equations to allow identification of wave-modes and edge-reflections. The effects of propagation distance and source orientation are investigated while comparison is made between the three specimens. It is concluded that while the wave propagation modes can be approximated as being constant throughout all three specimens, there is a significant change in the received waveforms due to the attenuation of high-frequency components exhibited by the bonded specimen. These findings may be utilised to provide a deeper understanding of acquired AE data, improving the current abilities to identify, locate and characterise damage mechanisms occurring within adhesive joints, ultimately improving safety in the use of adhesive bonding for critical applications.

42 ENGINEERING↗

Faulting of natural serpentinite: Implications for intermediate-depth seismicity

The seismic potential of serpentinites at high pressure was investigated via deformation experiments on cored natural serpentinite samples, during which micro-seismicity was monitored by recording Acoustic Emissions (AEs). Deformation was performed at pressures of 3–5 GPa, using a Deformation-DIA device, and over a wide range of temperatures, both within and outside antigorite's stability field. Below 400 °C, serpentinite deformation involves “silent” semi-brittle mechanisms, even in cases where strain localization is observed. At high temperature (i.e., above 600 °C), despite conditions propitious to dehydration embrittlement (i.e., fast strain rates and reaction kinetics), joint deformation and dehydration lead to ductile shear, without generation of AEs. Brittle behavior was observed in a narrow temperature window ca. 500 °C. In this latter case, AEs are consistently observed upon faulting and extremely sharp strain localization is observed in recovered samples. The resulting microstructures are consistent with the inverse ductile-to-brittle transition proposed by Proctor and Hirth (2016) in antigorite. This may therefore be a source of seismicity in subducting slabs at mantle pressures and temperatures from 500 to 600 °C. However, the acoustic signal observed here is orders of magnitude weaker than what is obtained at low PT conditions with brittle failure, consistently with low radiation efficiency of serpentinite faulting (Prieto et al., 2013) and suggests that other mechanisms are responsible for large intermediate-depth earthquakes. In fact, the present results are in line with a recent study (Ferrand et al., 2017), that suggests that intermediate earthquakes are likely induced by mechanical instabilities due to dehydration in partly hydrated peridotites.

58 GEOSCIENCES↗

Laboratory system for studying cryogenic thermal rock fracturing for well stimulation

The concept of cryogenic fracturing is that a sharp thermal gradient developed by applying a cryogenic fluid on a rock surface causes a strong local tensile stress that initiates fractures. Prior field tests suggest that field application with special equipment rated for cryogenic temperatures may deliver potential benefits. The tests did not, however, identify the fracture mechanisms at work in downhole conditions. We present our laboratory designs and procedures developed for studying cryogenic fracturing mechanisms in a well environment, and examine typical data indicative of the performance of the system. The experimental apparatus and procedures were specifically designed to conduct cryogenic fracturing tests in specimens under confining stress, with integrated cryogen transport, measurements, and fracture characterization. A true-triaxial loading system was built to simulate reservoir stress levels and anisotropic stress application, and was designed to avoid thermal stresses in tests involving cryogen by arranging discrete components in an open chamber. To maximize thermal shock on the wellbore surface, tubing and wellhead are configured so that liquid nitrogen enters the borehole and flow out after contributing to thermal shock. The temperature at boreholes and along flow lines, borehole pressure, and liquid nitrogen consumption are monitored throughout treatments. Acoustic transmission and pressure-decay measurements are used to characterize fractures before and after the experiments. Breakdown tests performed on un-stimulated specimens and stimulated specimens compare breakdown pressures of the two groups and thus evaluate the performance of thermal fracturing. The laboratory design was able to effectively apply cryogenic stimulations to laboratory rock specimens. Finally, the characterization methods were able to capture fracture creation and rock property changes due to cryogenic fracturing.

54 ENVIRONMENTAL SCIENCES↗

Acoustic emission analysis on tensile failure of steam-side oxide scales formed on T22 alloy superheater tubes

Failure of steam-side oxide scales on boiler tubes can seriously influence the safety of coal-fired power plants. Uniaxial tensile tests employing acoustic emission (AE) monitoring were performed, in this work, to investigate the failure behavior of steam-side oxide scales on T22 alloy boiler superheater tubes. The characteristic frequency spectra of the captured AE signals were obtained by performing fast Fourier transform. Three distinct peak frequency bands, 100-170, 175-250, and 280-390 kHz, encountered in different testing stages were identified in the frequency spectra, which were confirmed to, respectively, correspond to substrate plastic deformation, oxide vertical cracking, and oxide spalling with the aid of scanning electronic microscopy observations, and can thus be used for distinguishing different oxide failure mechanisms. Finally, the critical cracking strain of the oxide scale and the interfacial shear strength of the oxide/substrate interface were estimated, which are the critical parameters urgently desired for modeling the failure behavior of steam-side oxide scales on boiler tubes of coal-fired power plants.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗

A laser powder bed fusion system for operando synchrotron x-ray imaging and correlative diagnostic experiments at the Stanford Synchrotron Radiation Lightsource

Laser powder bed fusion (LPBF) is a highly dynamic multi-physics process used for the additive manufacturing (AM) of metal components. Improving process understanding and validating predictive computational models require high-fidelity diagnostics capable of capturing data in challenging environments. Synchrotron x-ray techniques play a vital role in the validation process as they are the only in situ diagnostic capable of imaging sub-surface melt pool dynamics and microstructure evolution during LPBF-AM. In this article, a laboratory scale system designed to mimic LPBF process conditions while operating at a synchrotron facility is described. The system is implemented with process accurate atmospheric conditions, including an air knife for active vapor plume removal. Significantly, the chamber also incorporates a diagnostic sensor suite that monitors emitted optical, acoustic, and electronic signals during laser processing with coincident x-ray imaging. The addition of the sensor suite enables validation of these industrially compatible single point sensors by detecting pore formation and spatter events and directly correlating the events with changes in the detected signal. Experiments in the Ti–6Al–4V alloy performed at the Stanford Synchrotron Radiation Lightsource using the system are detailed with sufficient sampling rates to probe melt pool dynamics. X-ray imaging captures melt pool dynamics at frame rates of 20 kHz with a 2 µm pixel resolution, and the coincident diagnostic sensor data are recorded at 470 kHz. Furthermore, this work shows that the current system enables the in situ detection of defects during the LPBF process and permits direct correlation of diagnostic signatures at the exact time of defect formation.

36 MATERIALS SCIENCE↗

Characterization of damage processes in Montney siltstone under triaxial compression using acoustic emission and diagnostic imaging

SUMMARY Crack nucleation and rock failure processes in a fine-grained siltstone (Montney Formation) under triaxial compression are investigated using combined diagnostic techniques, including ultrasonic-wave measurement, acoustic-emission (AE) monitoring, computed tomography (CT) scanning, and thin-section imaging. The sample displays a weak-to-moderate inherent seismic anisotropy and noticeable stress-induced anisotropy prior to failure. No AE event was detected until the applied axial stress reached 95 per cent of the peak value. The signal-to-noise ratio is relatively low, however, and detectable AE events are more diffuse than those observed in highly brittle rocks. The AE locations correlate with a shear fracture zone imaged by CT scanning. AE moment-tensor analysis reveals that events with larger relative magnitudes are characterized by high volumetric (tensile or compressive) components, and the initiation of the failure zone is dominated by combined shear-tensile (ST) failure. Stress inversion of the AE events with high tensile components is in good agreement with the known applied stress. Microscopic imaging of thin sections from the failed sample shows that the failure zone is an en echelon structure consisting of a major fracture with branching micro and minor cracks. This failure mechanism is consistent with a ST source mechanism and is interpreted to be associated with the fine granular structure and mineral composition of Montney siltstone.

Jia, Suzie Q. (ORCID:0000000326496190)↗

Wind Turbine Gearbox Condition Monitoring Vibration Analysis Benchmarking Datasets

Wind turbine condition monitoring (CM) can potentially help the wind industry reduce turbine downtime and operation and maintenance (O&M) cost. NREL CM research has investigated various condition-monitoring techniques such as acoustic emission (AE specifically stress wave), vibration, electrical signature, lubricant and debris monitoring based on the Gearbox Reliability Collaborative dynamometer and field tests, and other test turbines and resources accessible by NREL. During the past several years, NREL CM research has shown that there are very few validation and verification efforts on commercial wind turbine CM systems. One of the reasons might be limited benchmarking datasets accessible by stakeholders. To fill this gap, NREL executed a data collection effort. The targeted users of these datasets include those investigating vibration-based wind turbine CM research, evaluating commercially available vibration-based CM systems, or testing prototyped vibration-based CM systems. NREL collected data from a healthy and a damaged gearbox of the same design tested by the GRC. Vibration data were collected by accelerometers along with high-speed shaft RPM signals during the dynamometer testing. The healthy gearbox was only tested in the dynamometer. The damaged gearbox was first tested in the dynamometer and later sent to a wind farm close to NREL for field testing. In the field test, it experienced two loss-of-oil events that damaged its internal bearings and gear elements. The gearbox was brought back to NREL and it was retested in the dynamometer with CM systems deployed under controlled loading conditions that would not cause catastrophic failure of the gearbox. The objective of releasing these datasets to the public along with information about the real damage that occurred to the damaged gearbox is to provide the wind industry with some benchmarking datasets. These datasets will benefit research, development, validation, verification, and advancement of vibration-based wind condition-monitoring techniques. By accessing this data you acknowledge the terms outlined in the "License Information" document. Please contract Shawn Sheng (NREL) if you have any questions on the data or would like to collaborate on publications based on the datasets.

Array↗

Effects of moisture absorption on damage progression and strength of unidirectional and cross-ply fiberglass–epoxy composites

Fiber-reinforced-polymer composites (FRPs) possess superior mechanical properties and formability, making them a desirable material for construction of large optimized mechanical structures, such as aircraft, wind turbines, and marine hydrokinetic (MHK) devices. However, exposure to harsh marine environments can result in moisture absorption into the microstructure of the FRPs comprising these structures and often degrading mechanical properties. Specifically, laminate static and fatigue strengths are often significantly reduced, which must be considered in design of FRP structures in marine environments. A study of fiberglass epoxy unidirectional and cross-ply laminates was conducted to investigate hygrothermal effects on the mechanical behavior of a common material system used in wind applications. Several laminates were aged in 50 °C distilled water until maximum saturation was reached. Unconditioned control and the saturated samples were tested in quasi-static tension with the accompaniment of acoustic emission (AE) monitoring. Cross-ply laminates experienced a 54 % reduction in strength due to moisture absorption, while unidirectional laminate strengths were reduced by 40 %. Stress–strain curves and AE activity of the samples were analyzed to identify changes in damage progression due to aging.

Nunemaker, Jake D.↗

Signature analysis of acoustic emission from graphite/epoxy composites

Acoustic emissions were monitored for crack extension across and parallel to the fibers in a single ply and multiply laminates of graphite epoxy composites. Spectrum analysis was performed on the transient signal to ascertain if the fracture mode can be characterized by a particular spectral pattern. The specimens were loaded to failure quasistatically in a tensile machine. Visual observations were made via either an optical microscope or a television camera. The results indicate that several types of characteristics in the time and frequency domain correspond to different types of failure.

Russell, S. S.↗

Detection of acoustic emission from composite laminates using PVF2 transducers

Polyvinylidene fluoride (PVF2), a semicrystalline polymer exhibiting piezoelectricity, is presently used as a sensing transducer in acoustic emission (AE) monitoring of several different composite laminate materials in order to obtain both quasi-static and fatigue loading results. AE signals obtained from PVF2 transducers are compared with those obtained by standard AE sensors. It is noted that PVF2 transducers may, through the application of spectral signal analysis, be able to distinguish between two distinct failure modes which have been observed in two composite laminates of the same material, but employing different lamina stacking sequences.

Stiffler, R.↗

Examination of coating failure by acoustic emission

Coatings of NiCrAlY bond coat with a zirconia - 12 wt percent yttria overlay were applied to disc-shaped specimens of U-700 alloy. A waveguide of 1 mm diameter platinum was TIG welded to the specimen and allowed it to be suspended in a tubular furnace. The specimen was thermally cycled to 1150 C, and the acoustic emission (AE) monitored. The weight gain per thermal cycle was also measured. A computer system based on the IBM-XT microcomputer was used extensively to acquire the AE data with respect to temperature. This system also controlled the temperature by using a PD software loop. Several different types of AE analyses were performed. A major feature of these tests, not addressed by previous work in this area, was that the coatings covered 100 percent of the specimen and also that the AE was amplified at two different levels. It is believed that this latter feature allows a qualitative appraisal of the relative number of cracks per AE event. The difference in AE counts between the two channels is proportional to the number of cracks per AE event, and this parameter may be thought of as the crack density. The ratio of the AE count difference to the AE count magnitude of one channel is inversely proportional to the crack growth. Both of these parameters allow the crack distribution and crack growth within each specimen to be qualitatively followed during the thermal cycling operation. Recent results which used these principles will be presented.

Berndt, Christopher C.↗

Mean stress and the exhaustion of fatigue-damage resistance

Mean-stress effects on fatigue life are critical in isothermal and thermomechanically loaded materials and composites. Unfortunately, existing mean-stress life-prediction methods do not incorporate physical fatigue damage mechanisms. An objective is to examine the relation between mean-stress induced damage (as measured by acoustic emission) and existing life-prediction methods. Acoustic emission instrumentation has indicated that, as with static yielding, fatigue damage results from dislocation buildup and motion until dislocation saturation is reached, after which void formation and coalescence predominate. Correlation of damage processes with similar mechanisms under monotonic loading led to a reinterpretation of Goodman diagrams for 40 alloys and a modification of Morrow's formulation for life prediction under mean stresses. Further testing, using acoustic emission to monitor dislocation dynamics, can generate data for developing a more general model for fatigue under mean stress.

Berkovits, Avraham↗

Contact thermal shock test of ceramics

A novel quantitative thermal shock test of ceramics is described. The technique employs contact between a metal-cooling rod and hot disk-shaped specimen. In contrast with traditional techniques, the well-defined thermal boundary condition allows for accurate analyses of heat transfer, stress, and fracture. Uniform equibiaxial tensile stresses are induced in the center of the test specimen. Transient specimen temperature and acoustic emission are monitored continuously during the thermal stress cycle. The technique is demonstrated with soda-lime glass specimens. Experimental results are compared with theoretical predictions based on a finite-element method thermal stress analysis combined with a statistical model of fracture. Material strength parameters are determined using concentric ring flexure tests. Good agreement is found between experimental results and theoretical predictions of failure probability as a function of time and initial specimen temperature.

Rogers, W. P.↗

Room Temperature Creep Of SiC/SiC Composites

During a recent experimental study, time dependent deformation was observed for a damaged Hi-Nicalon reinforced, BN interphase, chemically vapor infiltrated SiC matrix composites subjected to static loading at room temperature. The static load curves resembled primary creep curves. In addition, acoustic emission was monitored during the test and significant AE activity was recorded while maintaining a constant load, which suggested matrix cracking or interfacial sliding. For similar composites with carbon interphases, little or no time dependent deformation was observed. Evidently, exposure of the BN interphase to the ambient environment resulted in a reduction in the interfacial mechanical properties, i.e. interfacial shear strength and/or debond energy. These results were in qualitative agreement with observations made by Eldridge of a reduction in interfacial shear stress with time at room temperature as measured by fiber push-in experiments.

Morscher, Gregory N.↗

Stress-Dependent Matrix Cracking in 2D Woven SiC-Fiber Reinforced Melt-Infiltrated SiC Matrix Composites

The matrix cracking of a variety of SiC/SiC composites has been characterized for a wide range of constituent variation. These composites were fabricated by the 2-dimensional lay-up of 0/90 five-harness satin fabric consisting of Sylramic fiber tows that were then chemical vapor infiltrated (CVI) with BN, CVI with SiC, slurry infiltrated with SiC particles followed by molten infiltration of Si. The composites varied in number of plies, the number of tows per length, thickness, and the size of the tows. This resulted in composites with a fiber volume fraction in the loading direction that ranged from 0.12 to 0.20. Matrix cracking was monitored with modal acoustic emission in order to estimate the stress-dependent distribution of matrix cracks. It was found that the general matrix crack properties of this system could be fairly well characterized by assuming that no matrix cracks originated in the load-bearing fiber, interphase, chemical vapor infiltrated Sic tow-minicomposites, i.e., all matrix cracks originate in the 90 degree tow-minicomposites or the large unreinforced Sic-Si matrix regions. Also, it was determined that the larger tow size composites had a much narrower stress range for matrix cracking compared to the standard tow size composites.

Morscher, Gregory N.↗

Microstructure-Sensitive Investigation of Fracture Using Acoustic Emission Coupled With Electron Microscopy

A novel technique using Scanning Electron Microscopy (SEM) in conjunction with Acoustic Emission (AE) monitoring is proposed to investigate microstructure-sensitive fatigue and fracture of metals. The coupling between quasi in situ microscopy with actual in situ nondestructive evaluation falls into the ICME framework and the idea of quantitative data-driven characterization of material behavior. To validate the use of AE monitoring inside the SEM chamber, Aluminum 2024-B sharp notch specimen were tested both inside and outside the microscope using a small scale mechanical testing device. Subsequently, the same type of specimen was tested inside the SEM chamber. Load data were correlated with both AE information and observations of microcracks around grain boundaries as well as secondary cracks, voids, and slip bands. The preliminary results are in excellent agreement with similar findings at the mesoscale. Extensions of the application of this novel technique are discussed.

Wisner, Brian↗