The application of acoustic emission method for ultrasonic fatigue testing monitoring


Cite item

Full Text

Abstract

The ultrasonic fatigue testing (USFT) is an effective method for rapid determination of the fatigue properties of structural materials under high cycle (≥106 cycles) loading. However, the occurrence and accumulation of fatigue damage with this test method remain uncertain due to the limitations of the existing measurement methods. Currently used monitoring methods allow detecting the fatigue cracks, but only in the late stages of failure. Despite the superior sensitivity to localized processes in materials, the use of the acoustic emission (AE) method in ultrasonic testing is extremely difficult due to the presence of resonant noise. This work aimed to suppress resonant noise and extract the signal for early detection of fatigue damage. The authors tested the samples of the AlSi9Cu3 aluminum alloy under the asymmetric cyclic loading (R=0.1) at a resonant frequency of 19.5 kHz with a non-threshold AE registration. The fracture surfaces were analyzed by electron and optical microscopy. The authors processed AE by two different methods: (1) the digital filtering method consisted of detecting resonant noise and removing it from the spectrum; (2) the φ-function method consisted of differentiating the spectrogram by time. The processed spectrograms were integrated by the frequency with further extraction of the AE events using the threshold method. The digital filtering method revealed a correlation between AE signals and fatigue damage, whereas the undamaged control sample showed no signals. The φ-function technique demonstrated ambiguous results, showing high AE activity on the control sample.

About the authors

Mikhail N. Seleznev

Freiberg University of Mining and Technology, Freiberg (Germany)

Author for correspondence.
Email: mikhail.seleznev@iwt.tu-freiberg.de
ORCID iD: 0000-0003-3158-9930

PhD (Physics and Mathematics), the researcher of the Institute of Materials Engineering

Germany

Aleksey Yu. Vinogradov

Norwegian University of Science and Technology, Trondheim (Norway)

Email: fake@neicon.ru
ORCID iD: 0000-0001-9585-2801

PhD (Physics and Mathematics), Professor of the Department of Engineering Design and Materials

Norway

References

  1. Mughrabi H. Fatigue, an everlasting materials problem – Still en vogue. Procedia Engineering, 2010, vol. 2, no. 1, pp. 3–26.
  2. Stanzl-Tschegg S.E. Time Saving Method for Measuring VHC Fatigue and Fatigue Crack Growth Data with the Ultrasonic Fatigue Technique. Procedia Structural Integrity, 2016, vol. 2, pp. 3–10.
  3. Zimmermann M. Very High Cycle Fatigue. Handbook of Mechanics of Materials. Singapore, Springer Publ., 2018, pp. 1–38.
  4. Si Y., Rouse J.P., Hyde C.J. Potential difference methods for measuring crack growth: A review. International Journal Fatigue, 2020, vol. 136, article number 105624.
  5. Kumar A., Torbet C.J., Jones J.W., Pollock T.M. Nonlinear ultrasonics for in situ damage detection during high frequency fatigue. Journal Applleted Physics, 2009, vol. 106, no. 2, article number 024904.
  6. Jhang K.-Y. Nonlinear ultrasonic techniques for nondestructive assessment of micro damage in material: A review. International Journal of Preciston Engineering and Manufacturing, 2009, vol. 10, no. 1, pp. 123–135.
  7. Lage Y., Cachao H., Reis L., Fonte M., De Freitas M., Ribeiro A. A damage parameter for HCF and VHCF based on hysteretic damping, International journal of fatigue, 2014, vol. 62, pp. 2–9.
  8. Krewerth D., Lippmann T., Weidner A., Biermann H. Application of full-surface view in situ thermography measurements during ultrasonic fatigue of cast steel G42CrMo4. International journal of fatigue, 2015, vol. 80, pp. 459–467.
  9. Wadley H.N.G., Mehrabian R. Acoustic Emission for Materials Processing : a Review. Materials Science and Engineering, 1984, vol. 65, no. 2, pp. 245–263.
  10. Chai M., Zhang J., Zhang Z., Duan Q., Cheng G. Acoustic emission studies for characterization of fatigue crack growth in 316LN stainless steel and welds. Applied acoustics, 2017, vol. 126, pp. 101–113.
  11. Noorsuhada M.N. An overview on fatigue damage assessment of reinforced concrete structures with the aid of acoustic emission technique. Construction and Building Materials, 2016, vol. 112, pp. 424–439.
  12. Saeedifar M., Zarouchas D. Damage characterization of laminated composites using acoustic emission: A review. Composites Part B: Engineering, 2020, vol. 195, article number 108039.
  13. Holford K.M., Eaton M.J., Hensman J.J., Pullin R., Evans S.L., Dervilis N., Worden K. A new methodology for automating acoustic emission detection of metallic fatigue fractures in highly demanding aerospace environments: An overview. Progress Aerospace Sciences, 2017, vol. 90, pp. 1–11.
  14. Du Y., Zhou S., Jing X., Peng Y., Wu H., Kwok N. Damage detection techniques for wind turbine blades: A review. Mechanical Systems and Signal Processing, 2020, vol. 141, article number 106445.
  15. Vinogradov A., Patlan V., Hashimoto S. Spectral analysis of acoustic emission during cyclic deformation of copper single crystals. Philosophical Magazine A: Physics of Condensed Matter, Structure, Defects and Mechanical Properties, 2001, vol. 81, no. 6, pp. 1427–1446.
  16. Chai M., Zhang Z., Duan Q. A new qualitative acoustic emission parameter based on Shannon’s entropy for damage monitoring. Mechanical Systems and Signal Processing, 2018, vol. 100, pp. 617–629.
  17. Kotzem D., Arold T., Niendorf T., Walther F. Damage tolerance evaluation of E-PBF-manufactured inconel 718 strut geometries by advanced characterization techniques. Materials, 2020, vol. 13, no. 1, pp. 247–248.
  18. Shiwa M., Furuya Y., Yamawaki H., Ito K., Enoki M. Fatigue process evaluation of ultrasonic fatigue testing in high strength steel analyzed by acoustic emission and Non-linear ultrasonic. Materials Transactions, 2010, vol. 51, no. 8, pp. 1404–1408.
  19. Agletdinov E., Merson D., Vinogradov A. A new method of low amplitude signal detection and its application in acoustic emission. Applied Sciences (Switzerland), 2020, vol. 10, no. 1, article number 73.
  20. Becker H., Bergh T., Vullum P.E., Leineweber A., Li Y. Effect of Mn and cooling rates on α-, β- and δ-Al–Fe–Si intermetallic phase formation in a secondary Al–Si alloy. Materialia, 2019, vol. 5, article number 100198.
  21. Scholkmann F., Boss J., Wolf M. An efficient algorithm for automatic peak detection in noisy periodic and quasi-periodic signals. Algorithms, 2012, vol. 5, no. 4, pp. 588–603.
  22. Zerbst U., Madia M., Klinger C., Bettge D., Murakami Y. Defects as a root cause of fatigue failure of metallic components. II: Non-metallic inclusions. Engineering Failute Analysis, 2019, vol. 98, pp. 228–239.
  23. Murakami Y. Metal Fatigue Effects of Small Defects and Nonmetallic Inclusions. USA, Elsevier Ltd. Publ., 2002. 369 p.
  24. Suresh S. Fatigue of materials. 2nd ed. Cambridge, University Press Publ., 1998. 679 p.
  25. Fischer H. Untersuchungen zum einfluss einer schmelzekonditionierung von AlSi9Cu3 auf die mikrostrukturelle ausprägung und die ermüdungslebensdauer. TU Bergakademie Freiberg, 2020. 58 p.
  26. Seleznev M., Weidner A., Biermann H. On the formation of ridges and burnished debris along internal fatigue crack propagation in 42CrMo4 steel. Fatigue Fracture of Engineering Materials and Structures, 2020, vol. 43, no. 7, pp. 1567–1582.
  27. Seleznev M., Merson E., Weidner A., Biermann H. Evaluation of very high cycle fatigue zones in 42CrMo4 steel with plate-like alumina inclusions. International Journal of Fatigue, 2019, vol. 126, pp. 258–269.
  28. Toda H., Sinclair I., Buffiere J.-Y., Maire E., Khor K.H., Gregson P., Kobayashi T. A 3D measurement procedure for internal local crack driving forces via synchrotron X-ray microtomography. Acta Materialia, 2004, vol. 52, no. 5, pp. 1305–1317.
  29. Davidson D., Chan K., McClung R., Hudak S. Small fatigue cracks. Comprehensive Structural Integrity, 2007, vol. 4, pp. 129–164.
  30. Xu L., Wang Q., Zhou M. Micro-crack initiation and propagation in a high strength aluminum alloy during very high cycle fatigue. Materials Science and Engineering A, 2018, vol. 715, pp. 404–413.
  31. Zerbst U., Madia M., Klinger C., Bettge D., Murakami Y. Defects as a root cause of fatigue failure of metallic components. I: Basic aspects. Engineering Failure Analysis, 2019, vol. 97, pp. 777–792.

Supplementary files

Supplementary Files
Action
1. JATS XML
Download

Copyright (c)



This website uses cookies

You consent to our cookies if you continue to use our website.

About Cookies