Evaluation of structural defects in brazed ceramic-to-metal joints with C-mode scanning acoustic microscopy

Structural defects and the integrity of brazed aluminium nitride-to-metal joints were studied by using C-mode scanning acoustic microscopy. Lack of bonding, cracks at the nitride/braze interface and surface opening cracks were clearly detected. The comparison of C-SAM results with those of scanning electron microscopy showed good correlation and demonstrated the high resolution of acoustic microscopy especially for detecting surface cracks.     

Use of the implant test and acoustic emission technique to investigate hydrogen‐assisted cracking in the fusion zone of welded HSLA‐80 steel

Summary

Hydrogen‐assisted cracking in the fusion zone (FZ) was studied, using flux‐cored wire (AWS E 70T5 and AWS E 120 T5‐K4) and a CO₂ + 5% H₂ gas mixture to induce high values of diffusible hydrogen in high strength, low alloy steel (HSLA‐80) welds. An acoustic emission measurement system (AEMS) based on a root mean square (RMS) voltmeter was coupled to the implant test apparatus (NF 89–100) to determine energy, amplitude and number of signals. Using optical microscopy and scanning electron microscopy (SEM), it was observed that, in all tests, cracks were initiated in the partially molten zone and propagated in the coarse‐grained region of the heat affected zone (HAZ) when E 70 T5 wire was used and quasi‐cleavage (QC) fracture mode was predominant. When E 120 T5 K.4 wire was used, the cracks were propagated vertically across the FZ and the mixed fracture mode was predominant. A significant relationship between acoustic emission (AE) parameters and fracture modes was found in the cracking mechanism.     

The effect of boron on the thermal fatigue behavior of Iron-chromium-carbon-silicon alloy

The effect of boron on the thermal fatigue behavior of Fe-20Cr-1.7C-1.0Si-xB (x = 0, 0.3 and 0.6 wt.%) hardfacing alloys was investigated using a high frequency induction heating/water cooling system. Formation and growth of thermal fatigue cracks in tested alloys was also investigated, and the effect of the strain-induced martensitic transformation on cracking was analyzed by means of optical microscopy and by nondestructive testing using ultrasonic elastic waves. These experiments demonstrated that the alloy exhibits sustained resistance to thermal fatigue in its early stages since the strain-induced martensitic transformation interfered with the propagation of fatigue cracks.     

Ta氧化膜开裂的临界应力

本工作将测量金属氧化膜内应力的单面弯曲法和检测氧化膜破裂的声发射技术相结合,建立了金属氧化膜开裂临界应力的测试装置。即从声发射信号判定氧化膜第一次开裂的时间,并由相应的氧化偏转曲线求得氧化膜开裂临界立力。纯 Ta 试样的测量结果表明,在500℃、550℃、600℃1atm O_2中,Ta 氧化膜开裂的临界应力分别为:23.3、38.5、18.4×10~6kgf/m~2。不论Ta 遵循直线型还是抛物线型氧化规律,只要时间足够长,恒温氧化中膜都会破裂;且破裂的临界应力和膜的疏密程度及开裂方式有关。     

基于声发射信号模式的齿轮特征识别研究

鉴于声发射信号对齿轮早期裂纹具有独特的敏感性,对早期齿轮声发射信号的特征识别具有重要意义。介绍小波变换理论及其原理,建立齿轮疲劳试验平台,利用小波阈值降噪对不同工况下齿轮声发射信号进行预处理,获取高能量频段的信号并提取时域、频域特征参数,将其作为BP神经网络的输入,以识别不同工况下的声发射信号。实验结果表明：与去噪后的全频段信号相比,基于高能量频段信号所提取的特征参数具有更高的识别率,为早期齿轮故障信号分析和检测提供借鉴。     

Frequency analysis of AE signal obtained during breakaway oxidation and internal cracking of 2 1/4Cr-1Mo steel at 900°C

The acoustic emission (AE) signal obtained during breakaway oxidation and internal cracking of 2 1/4Cr-1Mo steel at 900°C was analysed over its frequency domain. Three regions, namely pre-breakaway, post-breakaway, and internal cracking were distinguished and confirmed by thermogravimetric analysis and scanning electron microscopy observations. The frequency analysis of the AE signal obtained in the three different regions showed three different characteristic patterns. Frequency spectra based on predominant frequencies were correlated with the physical phenomena happening during the course of oxidation.     

超声冲击处理冷轧钢板缝焊接头的疲劳性能

用窄搭接电阻缝焊机对汽车用SPCC（冷轧低碳普通钢板）进行焊接,采用超声冲击仪对缝焊接头进行处理;通过拉压疲劳试验、X射线应力分析仪、OM、SEM对处理和未处理的缝焊接头疲劳性能和组织进行测试和观察分析对比.结果表明,未经超声冲击处理的缝焊接头经5×104次交变载荷作用即在焊趾区萌生裂纹,裂纹与载荷方向呈45°;经超声冲击处理过的缝焊接头经1.88×106次交变载荷作用未发生断裂;超声冲击处理使缝焊接头表层晶粒细化并形成塑性变形层,降低了其表面的微裂纹缺陷造成的应力集中,使表面残余拉应力变为了压应力,有利于改善缝焊接头的疲劳性能.     

四点弯曲条件下热障涂层断裂模式的声发射表征

采用声发射技术实时监测喷涂态8% Y₂O₃稳定的ZrO₂（8YSZ）在四点弯曲载荷下的损伤断裂行为。采用特征参数分析、聚类分析和小波包变换分析声发射信号结合涂层的微观形貌和应力状态,从而推测出热障涂层系统的失效形式。结果表明：内弯和外弯两种加载模式下,均各有4种失效行为。宏观断裂对应的剥落信号无明显频带,而基底变形、表面垂直裂纹、张开型界面裂纹和剪切型界面裂纹信号对应的主频带可清晰区分为：0~156.25 kHz、156.25~234.375 kHz、312.625~390.625 kHz和390.625~468.75 kHz。热障涂层在外弯载荷下,表面垂直裂纹不断出现,随后扩展到粘结层-陶瓷层界面处并转化为张开型界面裂纹;而在内弯载荷下,则在粘结层-陶瓷层界面附近产生剪切型界面裂纹,仅出现少量的表面垂直裂纹。两种界面裂纹均会引起热障涂层的宏观裂纹和剥落。     

圆柱表面声波辅助剪切增稠抛光优化实验研究

目的获得声波辅助剪切增稠抛光方法抛光轴承钢圆柱表面的最佳工艺参数。方法应用田口法,对声波辅助剪切增稠抛光过程中影响工件材料去除率,以及表面粗糙度的声波频率、声波功率、声波波形等参数进行实验与优化分析,以材料去除率、表面粗糙度为评价条件,得到最优抛光参数,并在最优参数条件下做多组重复性实验以验证结果的可靠性。利用金相显微镜、光学轮廓仪等测试手段对加工后的工件进行表面形貌检测。结果以材料去除率为评价指标,声波频率影响最为显著,声波功率影响次之,声波波形影响最小;以表面粗糙度为评价指标时,声波波形影响最为显著,声波频率影响次之,声波功率影响最小。结论在声波频率为20 Hz、声波功率为25 W、正弦波形条件下,工件材料去除率最高,材料去除率达到了11.32μm/h;在声波频率为60 Hz、声波功率25 W、正弦波形条件下,工件表面质量最佳,抛光1 h后工件平均表面粗糙度Ra由100 nm下降至7 nm以内,最低达到了4.48 nm。     

Room temperature tensile deformation behavior of a Ni-based superalloy with high W content

K416B Ni-based superalloy with high W content has good high temperature properties and low cost, which has a great development potential. To investigate the room temperature tensile property and the deformation feature of K416B superalloy, tensile testing at room temperature was carried out, and optical microscopy (OM), scanning electron microscopy (SEM) and transmission electron microscopy (TEM) were used to analyze the deformation and damage mechanisms. Results show that the main room temperature tensile deformation features of the K416B nickel-based superalloy are dislocations slipping in the matrix and shearing into γ′ phase. The <110> super-dislocations shearing into γ′ phase can form the anti-phase boundary two coupled (a/2)<110> partial-dislocations or decompose into the configuration of two (a/3)<112> partial dislocations plus stacking fault. In the later stage of tensile testing, the slip-lines with different orientations are activated in the grain, causing the stress concentration in the regions of block carbide or the porosity, and cracks initiate and propagate along these regions.

     

Stress corrosion cracking detection using non-contact ultrasonic techniques

In this work a method is presented for detecting and locating stress corrosion cracking (SCC) in stainless steel pipe samples. The method combines laser generation and either laser or electromagnetic acoustic transducer (EMAT) detection, scanning the generation point across the sample surface. Using laser-generated ultrasonic waves that interact with the cracks, and performing time–frequency analysis techniques to examine changes in the generated wavemodes, surface plots that clearly resolve the spatial extent and geometric alignment of the cracks are created and presented here. The method is demonstrated using components removed from service after exhibiting SCC.     

Materials characterization and flaw detection by acoustic NDE

For many years, researchers have used internal friction to characterize structural inhomogeneities or flaws in a material by using the frequency or temperature dependence of the acoustic loss mechanisms connected with these inhomogeneities. The field of materials characterization and flaw detection by acoustic nondestructive evaluation (NDE) thus has a broad fundamental base. This knowledge base is of great interest in that it is useful for nondestructive characterization and, particularly, to determine the effect of these inhomogeneities on the overall performance of the material. A variety of inhomogeneities can be studied by acoustic NDE, including interstitials, precipitates, dislocations, grains, phase transformations, porosity, and cracks.     

Study of the performance of TBC under thermal cycling conditions using an acoustic emission rig

An experimental rig based on the use of infrared quartz lamps has been developed to monitor the degradation mechanisms causing failure of thermal barrier coatings (TBC) under thermal-cycling conditions. An acoustic emission (AE) technique monitored these degradation mechanisms, and advanced signals processing identified the key parameters that classify the AE signals according to the long-term behavior of the TBC. The AE technique enabled the localization of degradation sources inside the TBC with a linear resolution of ∼5 mm by the use of two transducers fixed at both ends of the sample. Furthermore, sample zones of high AE activity showed typical vertical cracks at the surface and delaminations at the interface between the ceramic and the bond-coat layer. Vertical cracks were induced preferentially during the heating period of the thermal cycles when the ceramic coating was in a tensile-stress state, while delaminations were induced during the cooling period when the TBC was in a compressive-stress state.     

Polycrystalline diamond cutting element control using high frequency C-scan image processing

The quality control of drilling tools used in the oil industry essentially consists of testing the cutting elements distributed around the petroleum tool. This study presents a nondestructive testing (NDT) method for the detection of different kinds of defects inside polycrystalline diamond cuttine elements (PDC). This ultrasonic method, based on high frequency (100 MHz) C-scan image processing, allows the detection of three major types of defect such as diamond layer debonding from the substrate, cracks and thermal defects of the diamond layers. These defects induce a perfectly quantified behaviour to mechanical abrasion resistance and fatigue tests. Experimental results show good correlation between our ultrasonic measurements and classical abrasion resistance tests. In fact, a PDC sample exhibiting defects detected by the C-scan technique has been submitted to a mechanical fatigue process and optical microscopic analysis. These tests have shown that each kind of defect has an influence on one or more mechanical characteristics. Using C-mode scanning acoustic microscopy (with a 50 μm pixel size), allows an extremely precise and quantified level of erosion resistance of the cutting elements without systematic resort to expensive destructive tests carried out during the reception of the batch. The rejection of samples showing harmful defects will eliminate the erratic and sometimes unexplained destruction of some tools which were considered to be defect-free.     

Acoustic emission analysis on tensile failure of air plasma-sprayed thermal barrier coatings

An acoustic emission technique was used to monitor the cracking behavior and fracture process of thermal barrier coatings subjected to tensile loading. Acoustic emission signals were extracted and preformed by fast Fourier transform, and their characteristic frequency spectrums and dominant bands were obtained to reveal fracture modes. Three different characteristic frequency bands were confirmed, corresponding to substrate deformation, surface vertical cracking and interface delamination, with the aid of scanning electronic microscopy observations. A map of the tensile failure mechanism of air plasma-sprayed thermal barrier coatings was established. The fracture strength and interfacial shear strength were estimated as 45.73 ± 3.92 MPa and 20.51 ± 1.74 MPa, respectively, which are well in agreement with available results.     

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 某轧钢厂正常轧制的钢材表面存在裂纹缺陷。利用扫描电子显微镜和金相显微镜对裂纹的形貌进行观察,发现裂纹附近存有高温氧化产物,经腐蚀后裂纹附近脱碳严重。由此可知：为连铸坯的表面裂纹,在经加热的过程中产生高温氧化,而正常的热轧工艺无法使其焊合,最终在钢材表面表现为裂纹缺陷。     

高聚物粘结炸药热冲击过程中的声发射现象研究

通过水浴冲击对高聚物粘结炸药（PBX）进行热冲击试验，由于材料在热冲击下产生的热应力来不及释放，从而导致材料内部产生裂纹。利用声发射仪器对热冲击过程进行监测，获得炸药材料在热冲击过程中的声发射信号。研究结果表明，声发射信号能够很好地反映热冲击过程中PBX损伤的产生和演变，并能够对损伤位置进行准确的定位，从而为研究材料的热冲击损伤机理和模式提供可靠的试验数据和理论依据。     

Structural and morphological modification of PDMS thick film surfaces by ion implantation with the formation of strain-induced buckling domains

Elastomer films with three-dimensional features self-organized into coherent and semi-coherent buckling domains were created by implanting different species of metal ions and combinations thereof, using a metal evaporation ion source, into quality polydimethylsiloxane films. As a result of the implantation process, functionalized discrete regions of strain-induced surface buckling were created, taking the forms of domains of parallel surface waves, semi-ordered regions and disordered regions. In addition, deep, strain-induced, V-shaped cracks were observed to penetrate well into the elastomer matrix. Characterization was via optical microscopy, X-ray diffraction, atomic force microscopy and high-resolution scanning electron microscopy (SEM) in the form of field emission SEM. It was found that controlling the localized strain by altering the metal ion species can control the frequency of the V-shaped cracks and the properties of the buckled areas. These observations and possible mechanisms for the formation of the cracks and domains are discussed in this paper.     

In Situ Acoustic Monitoring of Thermal Spray Process Using High-Frequency Impulse Measurements

In order to guarantee their protective function, thermal spray coatings must be free from cracks, which expose the substrate surface to, e.g., corrosive media. Cracks in thermal spray coatings are usually formed because of tensile residual stresses. Most commonly, the crack occurrence is determined after the thermal spraying process by examination of metallographic cross sections of the coating. Recent efforts focus on in situ monitoring of crack formation by means of acoustic emission analysis. However, the acoustic signals related to crack propagation can be absorbed by the noise of the thermal spraying process. In this work, a high-frequency impulse measurement technique was applied to separate different acoustic sources by visualizing the characteristic signal of crack formation via quasi-real-time Fourier analysis. The investigations were carried out on a twin wire arc spraying process, utilizing FeCrBSi as a coating material. The impact of the process parameters on the acoustic emission spectrum was studied. Acoustic emission analysis enables to obtain global and integral information on the formed cracks. The coating morphology and coating defects were inspected using light microscopy on metallographic cross sections. Additionally, the resulting crack patterns were imaged in 3D by means of x-ray microtomography.     

Acoustic emission technique: An alternative method to study the brittle oxide formed on copper

The acoustic emission technique has been utilized as an alternative technique to thermogravimetry to study the anomalous behavior of copper metal oxidation at 500°C The present work demonstrates an excellent example of the application of this technique in detecting cracks in growing oxide films.