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At least 109 records · Page 6

Analyzing acoustic emission data to identify cracking modes in cement paste using an artificial neural network

This research is focused on the identification of cracking mechanisms for cement paste using acoustic emission data, recorded from compression and notched four-point bending tests. A procedure is developed for analyzing the data by employing an agglomerative hierarchical clustering method, an artificial neural network, and a ray-tracing source location algorithm. An agglomerative hierarchical clustering method is utilized to cluster the AE data from a compression test using frequency-dependent features. A neural network is trained using the compression test data and applied to the AE data emitted during the four-point bending test. The clustered data from the four-point bending test is localized using a ray-tracing algorithm. Based on the occurrence and locations of the clustered events and signal feature analyses, potential cracking mechanisms are identified and assigned.

36 MATERIALS SCIENCE↗

Certifying Acoustic Emission for the Crack Inspection of Integrated Pressure Components

To address the limitations of other nondestructive evaluation (NDE) methods on integrated components due to access constraints, a novel Acoustic Emission (AE) pressure vessel health test was developed in accordance with ASME BPVC.V Article 12. This test was then validated using notched Ti-6Al-4V panels taken to a stress level equivalent to 1.1 times the Maximum Allowable Working Pressure (MAWP) of a flight pressure vessel. The assessment involved utilizing JSC small sample Probability of Detection (POD) calculations, which represents the initial step towards obtaining flight certification for an NDE technique. A robust filtering technique that specifically identifies crack growth was formulated with the assistance of industry partners. This detection method exhibited superior detection ability compared to other NDE methods or microscopy. Within industry, the presence of a group of triangulated energetic crack-like indications typically leads to supplemental inspection or the failure of a tank. The experimental results confirm that this approach, commonly applied to more robust tanks, can be viably extended to integrated aerospace pressure components in scenarios where components can be subjected to pressures up to 1.1 times the MAWP. The testing process encountered delays due to sensor delivery and panel fabrication. Thus far, samples with crack initiators have shown energy levels 10 times higher than blunted controls. This suggests a trend where high individual and total cluster energy could be employed as acceptance criteria. Moreover, the cumulative energy of clusters might serve as a foundation for estimating crack sizes; however, this aspect requires further assessment and localized supplemental inspections are preferred.

certifying↗

On the anatomy of acoustic emission

Abrupt, local frictional fault failure comprises a displacement that is normally accompanied by acoustic emission (AE)—an impulsive elastic wave broadcast with an amplitude proportional to particle velocity. The aggregate of these displacements is the basic fault motion. In laboratory shear experiments, the examination of a sequence of laboratory earthquakes includes continuous measurements of fault motion and the associated AE that is broadcast. From these measurements, connections between the fault motion and cumulative sum of the AE amplitude can be identified. The composition of the AE broadcasts reveals inhomogeneity in the fault mechanical structure from which they arise. This inhomogeneity can be decomposed into a time invariant AE component and an articulated AE component. The articulated AE component serves as a “state of the fault diagnostic” that follows a distinctive pattern to fault failure. Thus, the articulated AE component can be used directly to monitor the state of the fault.

71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗

Punch stretching process monitoring using acoustic emission signal analysis. II - Application of frequency domain deconvolution

The coloring effect on the acoustic emission signal due to the frequency response of the data acquisition/processing instrumentation may bias the interpretation of AE signal characteristics. In this paper, a frequency domain deconvolution technique, which involves the identification of the instrumentation transfer functions and multiplication of the AE signal spectrum by the inverse of these system functions, has been carried out. In this way, the change in AE signal characteristics can be better interpreted as the result of the change in only the states of the process. Punch stretching process was used as an example to demonstrate the application of the technique. Results showed that, through the deconvolution, the frequency characteristics of AE signals generated during the stretching became more distinctive and can be more effectively used as tools for process monitoring.

Liang, Steven Y.↗

Acoustic emission monitoring of low velocity impact damage in graphite/epoxy laminates during tensile loading

An acoustic emission (AE) system was set up in a linear location data acquisition mode to monitor the tensile loading of eight-ply quasi-isotropic graphite/epoxy specimens containing low velocity impact damage. The impact damage was induced using an instrumented drop weight tower. During impact, specimens were supported by either an aluminum plate or a membrane configuration. Cross-sectional examinations revealed that the aluminum plate configuration resulted in primarily matrix cracking and back surface fiber failure. The membrane support resulted in only matrix cracking and delamination damage. Penetrant enhanced radiography and immersion ultrasonics were used in order to assess the amount of impact damage in each tensile specimen. During tensile loading, AE reliably detected and located the damage sites which included fiber failure. All specimens with areas of fiber breakage ultimately failed at the impact site. AE did not reliably locate damage which consisted of only delaminations and matrix cracking. Specimens with this type of damage did not ultimately fail at the impact site. In summary, AE demonstrated the ability to increase the reliability of structural proof tests; however, the successful use of this technique requires extensive baseline testing.

Parker, Bradford H.↗

Acoustic Emission Analysis of Damage Progression in Thermal Barrier Coatings Under Thermal Cyclic Conditions

Damage evolution of electron beam-physical vapor deposited (EBVD-PVD) ZrO2-7 wt.% Y2O3 thermal barrier coatings (TBCs) under thermal cyclic conditions was monitored using an acoustic emission (AE) technique. The coatings were heated using a laser heat flux technique that yields a high reproducibility in thermal loading. Along with AE, real-time thermal conductivity measurements were also taken using infrared thermography. Tests were performed on samples with induced stress concentrations, as well as calcium-magnesium-alumino-silicate (CMAS) exposure, for comparison of damage mechanisms and AE response to the baseline (as-produced) coating. Analysis of acoustic waveforms was used to investigate damage development by comparing when events occurred, AE event frequency, energy content and location. The test results have shown that AE accumulation correlates well with thermal conductivity changes and that AE waveform analysis could be a valuable tool for monitoring coating degradation and provide insight on specific damage mechanisms.

calcium-magnesium-alumino-silicate (CMAS)↗

Acoustic Emissions Could Indicate Weld Quality

Preliminary tests show quality of welds can be assessed by acoustic-emission monitor mounted on welder. Nondestructive measurement technique allows operator to determine uniformity and integrity of weld as being made, evaluate equipment performance and condition, and initiate corrective action if quality is not satisfactory.

Gustafson, P. E.↗

A study of aluminum-lithium alloy solidification using acoustic emission techniques

Physical phenomena associated with the solidification of an aluminum lithium alloy was characterized using acoustic emission (AE) techniques. It is shown that repeatable patterns of AE activity may be correlated to microstructural changes that occur during solidification. The influence of the experimental system on generated signals was examined in the time and frequency domains. The analysis was used to show how an AE signal from solidifying aluminum is changed by each component in the detection system to produce a complex waveform. Conventional AE analysis has shown that a period of high AE activity occurs in pure aluminum, an Al-Cu alloy, and the Al-Li alloy, as the last fraction of solid forms. A model attributes this to the internal stresses of grain boundary formation. An additional period of activity occurs as the last fraction of solid forms, but only in the two alloys. A model attributes this to the formation of interdendritic porosity which was not present in the pure aluminum. The AE waveforms were dominated by resonant effects of the waveguide and the transducer.

Henkel, Daniel P.↗

Acoustic Emission and Damage Accumulation for Various Woven C/SiC Composites Tested in Tension at Room Temperature

Modal acoustic emission (AE) has proven to be an excellent technique to monitor damage accumulation in ceramic matrix composites. In this study, AE was used to monitor tensile load-unload-reload hysteresis tests for a variety of C fiber reinforced, SiC matrix composites. C/SiC composites were reinforced with T300 and IM7 fibers, had C, multilayer, or pseudo-porous C interphases, and had chemical vapor infiltrated SiC or melt-infiltrated SiC matrices. All of the composites exhibited considerable AE during testing. The extent and nature of the AE activity will be analyzed and discussed in light of matrix cracking and the variety of composite constituents. It is hoped that understanding the nature of stress dependent damage accumulation in these materials can be of use in life modeling for these types of composites.

Morscher, Gregory N.↗

Acoustic Emission and Damage Accumulation for Various Woven C/SiC Composites Tested in Tension at Room Temperature

Modal acoustic emission (AE) has proven to be an excellent technique to monitor damage accumulation in ceramic matrix composites. In this study, AE was used to monitor tensile load-unload-reload hysteresis tests for a variety of C fiber reinforced, Sic matrix composites. C/SiC composites were reinforced with T-300 and IM7 fibers, had C, multilayer, or pseudo-porous C interphases, and had chemical vapor infiltrated Sic or melt-infiltrated SiC matrices. All of the composites exhibited considerable AE during testing. The extent and nature of the AE activity will be analyzed and discussed in light of matrix cracking and the variety of composite constituents. It is hoped that understanding the nature of stress-dependent damage accumulation in these materials can be of use in life-modeling for these types of composites.

Morscher, Gregory↗

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↗

Acoustic emission from a growing crack

An analytical method is being developed to determine the signature of an acoustic emission waveform from a growing crack and the results of this analysis are compared to experimentally obtained values. Within the assumptions of linear elastic fracture mechanics, a two dimensional model is developed to examine a semi-infinite crack that, after propagating with a constant velocity, suddenly stops. The analytical model employs an integral equation method for the analysis of problems of dynamic fracture mechanics. The experimental procedure uses an interferometric apparatus that makes very localized absolute measurements with very high fidelity and without acoustically loading the specimen.

Jacobs, Laurence J.↗

Developing a heterogeneous ensemble learning framework to evaluate Alkali-silica reaction damage in concrete using acoustic emission signals

The monitoring and evaluation of Alkali-silica reaction (ASR) damage in concrete structures are required to ensure the serviceability and integrity of concrete infrastructures such as bridges and dams. The innovation of this paper lies in the development of an automatic ASR monitoring and evaluation approach by leveraging acoustic emission (AE) and a heterogeneous ensemble learning framework. Here, in this paper, ASR was monitored by AE sensors attached to a concrete specimen, which was placed in a chamber with high humidity and temperature. The recorded AE signals were filtered and divided by four ASR phases according to signal strength, crack width and expansion strain. A heterogeneous ensemble network including convolutional neural networks (CNN) and random forest models was employed to learn different features from AE signals and classify the AE signals into their corresponding phases. The results suggest that the proposed model has a high performance and classifies the signals into the assigned phases with high accuracy.

42 ENGINEERING↗

Acoustic Emission Monitoring of the DC-XA Composite Liquid Hydrogen Tank During Structural Testing

The results of acoustic emission (AE) monitoring of the DC-XA composite liquid hydrogen tank are presented in this report. The tank was subjected to pressurization, tensile, and compressive loads at ambient temperatures and also while full of liquid nitrogen. The tank was also pressurized with liquid hydrogen. AE was used to monitor the tank for signs of structural defects developing during the test.

Wilkerson, C.↗

Multiplexing Technology for Acoustic Emission Monitoring of Aerospace Vehicles

The initiation and propagation of damage mechanisms such as cracks and delaminations generate acoustic waves, which propagate through a structure. These waves can be detected and analyzed to provide the location and severity of damage as part of a structural health monitoring (SHM) system. This methodology of damage detection is commonly known as acoustic emission (AE) monitoring, and is widely used on a variety of applications on civil structures. AE has been widely considered for SHM of aerospace vehicles. Numerous successful ground and flight test demonstrations have been performed, which show the viability of the technology for damage monitoring in aerospace structures. However, one significant current limitation for application of AE techniques on aerospace vehicles is the large size, mass, and power requirements for the necessary monitoring instrumentation. To address this issue, a prototype multiplexing approach has been developed and demonstrated in this study, which reduces the amount of AE monitoring instrumentation required. Typical time division multiplexing techniques that are commonly used to monitor strain, pressure and temperature sensors are not applicable to AE monitoring because of the asynchronous and widely varying rates of AE signal occurrence. Thus, an event based multiplexing technique was developed. In the initial prototype circuit, inputs from eight sensors in a linear array were multiplexed into two data acquisition channels. The multiplexer rapidly switches, in less than one microsecond, allowing the signals from two sensors to be acquired by a digitizer. The two acquired signals are from the sensors on either side of the trigger sensor. This enables the capture of the first arrival of the waves, which cannot be accomplished with the signal from the trigger sensor. The propagation delay to the slightly more distant neighboring sensors makes this possible. The arrival time from this first arrival provides a more accurate source location determination. The multiplexer also identifies which channels are acquired by encoding TTL logic pulses onto the latter portion of the signals. This prototype system was demonstrated using pencil lead break (Hsu-Neilsen) sources on an aluminum plate. It performed as designed providing rapid low noise trigger based switching with encoded channel identification. this multiplexing approach is not limited to linear arrays, but can be easily extended to monitor sensors in planar ot three dimensional arrays. A 32 channel multiplexing system is under development that will allow arbitrary sensor placement. Another benefit of this multiplexing system is the reduction in the expense of data acquisition hardware. In addition, the reduced weight and power requirements are of extreme importance for proposed AE systems on aerospace vehicles.

Prosser, William↗

Shear band velocity and activation volume during shear deformation by acoustic emission in a Zr-based bulk metallic glass

Here, an analysis is presented for the shear band velocity of plastic deformation and activation volume of the shear transformation zone (STZ) in a Zr 60 Cu 30 Al 10 bulk metallic glass (BMG). Compared to the values calculated by the stick-slip model, the values of shear band velocity calculated after optimization by the acoustic emission technique are much larger than those reported previously. Plastic flow in BMGs is found to be described by a power-law correlation between the maximum velocity of the shear band and the strain rates. Combining the free volume theory and the STZ theory, the relationship between the volume change in the STZ and the shear band velocity is derived as $Ω=A$(27–ln$v/l$). The value of A, which is a material dependent constant, is 5.43 × 10 –3 for the current BMG at room temperature.

36 MATERIALS SCIENCE↗

Acoustic Emission Methods for the Health Evaluation of Integrated Pressure Components

At the request of the Pressure Systems Senior Discipline Expert, to overcome the access and detectable flaw size limitations of other nondestructive evaluation (NDE) methods for integrated components, a technique akin to seismology was advanced to perceive the earliest signs of cracking in titanium components before they escalate into serious issues. In this project we achieved a landmark in Acoustic Emission (AE) testing with the first NASA Probability of Detection (POD) study. This is an important first step to the certification of the AE method for flight components and was based on the testing of notched panels. By working closely with industry allies and employing approved methods from the boiler and pressure vessel sector, we not only met but surpassed all POD benchmarks with our test and acceptance criteria. In experiments involving solution heat-treated and aged 6Al-4V-Ti alloy tested with broadband sensors, we recorded a 96% success rate, with zero false positives reported. Our research shows that in some cases, AE testing can locate smaller cracks than other NDE methods. An industry tool for scaling results to full pressure vessels is highlighted. However, before applying our findings to NASA components, tests to validate the transfer functions are advised.

acoustic↗

Use of Statistical Analysis of Acoustic Emission Data on Carbon-Epoxy COPV Materials-of-Construction for Enhanced Felicity Ratio Onset Determination

Broadband modal acoustic emission (AE) data were acquired during intermittent load hold tensile test profiles on Toray T1000G carbon fiber-reinforced epoxy (C/Ep) single tow specimens. A novel trend seeking statistical method to determine the onset of significant AE was developed, resulting in more linear decreases in the Felicity ratio (FR) with load, potentially leading to more accurate failure prediction. The method developed uses an exponentially weighted moving average (EWMA) control chart. Comparison of the EWMA with previously used FR onset methods, namely the discrete (n), mean (n (raised bar)), normalized (n%) and normalized mean (n(raised bar)%) methods, revealed the EWMA method yields more consistently linear FR versus load relationships between specimens. Other findings include a correlation between AE data richness and FR linearity based on the FR methods discussed in this paper, and evidence of premature failure at lower than expected loads. Application of the EWMA method should be extended to other composite materials and, eventually, composite components such as composite overwrapped pressure vessels. Furthermore, future experiments should attempt to uncover the factors responsible for infant mortality in C/Ep strands.

Abraham, Arick Reed A.↗