Crack‐Tip Stress Field and Fatigue Crack Growth Monitoring Using Infrared Lock‐In Thermography in A359/SiCp Composites

Abstract: This paper deals with the study of fracture behaviour of silicon carbide particle‐ reinforced aluminium alloy matrix composites (A359/SiCp) using an innovative non‐destructive method based on lock‐in thermography. The heat wave, generated by the thermo‐mechanical coupling and the intrinsic energy dissipated during mechanical cyclic loading of the sample, was detected by an infrared camera. The coefficient of thermo‐elasticity allows for the transformation of the temperature profiles into stresses. A new procedure was developed to determine the crack growth rate using thermographic mapping of the material undergoing fatigue. The thermographic results on the crack growth rate of A359/SiCp composite samples with three different heat treatments were correlated with measurements obtained by the conventional compliance method. The results obtained by the two methods were found to be in agreement, demonstrating that lock‐in thermography is a powerful tool for fracture mechanics studies. The paper also investigates the effect of heat treatment processing of metal matrix composites on their fracture properties.     

Quantitative methods for structural health management using in situ acoustic emission monitoring

This paper presents an end-to-end approach for structural health management using acoustic emission (AE) monitoring. Three quantitative methods are proposed to utilize the information obtained from in situ AE monitoring to improve structural integrity assessment. Fatigue crack growth tests with real-time acoustic emissions monitoring are conducted on CT specimens made of 7075-T6 aluminum. Proper filtration of the resulting AE signals reveals a log-linear relationship between fracture parameters (e.g. crack growth rate) and select AE features; a flexible statistical model is developed to describe the relationship between these parameters. Bayesian inference is used to estimate the model parameters from experimental data. The model is then used to calculate two important quantities that can be used for structural health management: (a) an AE-based instantaneous damage severity index, and (b) an AE-based estimate of the crack size distribution at a given point in time, assuming a known initial crack size distribution. Finally, recursive Bayesian estimation is used for online integration of the structural health assessment information obtained from AE monitoring, with crack size estimates obtained from empirical crack growth model. The data used in Bayesian updating includes observed crack sizes and/or crack growth rate observations.     

SUS304不锈钢拉伸过程中的声-热像特征

测量了含有Ⅰ型裂纹的SUS304不锈钢试样的单轴拉伸过程中的塑性变形和断裂。分析了裂纹尖端区域的塑性变形和断裂过程。结果表明:SUS304的各向异性在断裂阶段对声发射信号影响较大;红外热图像中的温度分布与塑性应变率有关;通过声发射参数和红外热图像可以从微观和宏观两方面分析裂纹尖端区域的塑性变形和断裂。     

Determination of J–R curves of thermoplastic starch composites containing crossed quasi-unidirectional flax fiber reinforcement

Thermoplastic starch (MaterBi) composites reinforced with quasi-unidirectional flax fiber in cross-ply (CP) arrangement were produced by film stacking followed by hot pressing. These composites, containing various amount of flax, failed ductilely with pronounced crack growth. Therefore, to determine their fracture mechanical behaviour the J-integral resistance curve concept (J–R) was applied. As the crack growth could not be traced, attempt was made to use the located acoustic emission (AE) events for that purpose. It was established that weighting and smoothing the located cumulative AE amplitudes the crack path can be correctly reconstructed. This was proved by collating the AE results with those derived from infrared thermographic (IT) inspection. Knowing the crack propagation at each point of the force–displacement curves the J–R curves could be determined. Both critical or initiation J-integral and tearing modulus went through a minimum with increase of flax content in the composites.     

Carbon/epoxy composite delamination analysis by acoustic emission method under various environmental conditions

New multifunctional materials for aerospace industry with exceptional properties must be tested under various environmental conditions to find out possible scatter factors for evaluated properties. Delamination is a typical damage mode observed for laminated composites. Therefore, reliable information regarding the delamination growth behaviour is needed for all operational environments of an aircraft operated at cryogenic and elevated temperatures. In this paper, delamination crack growth monitoring in a climatic chamber on double-cantilever beam (DCB) specimens using optical devices and acoustic emission (AE) techniques is described. A relationship between cumulative AE energy, events localization, clusters, and crack growth in a plain-weave carbon fibre–reinforced epoxy is investigated under constant displacement rate loading at + 80 °C, and − 55 °C. Test results are evaluated for specimens with multi-walled carbon nanotubes (MWCNT) in the microstructure and for a reference material. The mechanical properties during delamination are represented by fracture toughness G_IC, and they are also correlated with the AE data. The elevated test temperature caused a decreased rate of released AE energy. The crack growth in material with more significant fibre breakage caused increase of the AE release rate.     

Acoustic emission study of fatigue crack closure of physical short and long cracks for aluminum alloy LY12CZ

Crack closure of physical short and long cracks of LY12CZ aluminum alloy during fatigue process was investigated using acoustic emission (AE) technique. Results showed that the effective fatigue crack growth curve (da/dN vs. ΔK_eff) of physical short and long cracks obtained by the AE technique was consistent with the effective fatigue crack growth curve at high stress ratio (R = 0.8), which implied that the AE technique could measure the crack closure level, especially for physical short crack. The growth rate of physical short crack was much higher than that of long crack at the same ΔK, and the lower crack closure level of short crack was the main reason.     

Quantitative acoustic emission source characterization of microcrackings in steel

Acoustic emission (AE) source wave analysis is a new NDE technique for the investigation of dynamic fracture process. We applied this technique to the quantitative characterization of crack sources in ductile fracture. Using two samples of ASTM A533B steel with different sulfur content, acoustic emissions during fracture toughness tests were detected, located, and analyzed. The detected AE signals were classified into two types according to the analyzed source waveforms. One was a signal due to microcracking at the MnS inclusion, and the other was a signal due to coalescence of the voids. The results of the source wave analysis showed that microcracking at the inclusions was due to Mode I type tension crack with sizes of 10–30 µm, and the coalescence of the voids was due to tension shear mixed cracks with sizes of 60–100 µm. It was confirmed that this technique is very effective for the quantitative evaluation of microcrackings and for the detection of the nucleation and growth of cracks.     

Acoustic emission from stress corrosion cracks in aligned GRP

Acoustic emission (AE) produced by the propagation of stress corrosion cracks in an aligned glass fibre/polyester resin composite material has been recorded. Tests have been carried out over a range of crack growth rates and the variation of AE with crack velocity/applied stress intensity has been examined. The main source of AE is fibre fracture and there is a one-to-one relationship between the number of fibre fractures and the number of high-amplitude AE signals. This enables crack growth to be monitored directly from acoustic emission. The amplitude of AE signals produced by fibre failure appears to be proportional to the fracture stress of the fibres, although further analysis requires a greater understanding of the generation, transmission and detection of AE signals. This work demonstrates that stress corrosion cracking is an ideal source for the study of AE produced by fibre fracture without complications caused by interface effects, such as fibre debonding or pullout.On leave from the Technical University of Wroclaw, Wroclaw, Poland.     

基于声发射技术的非标准自密实混凝土三点弯曲梁动态断裂特性

对不同初始缝高比的自密实混凝土(Self-compacting concrete,SCC)非标准三点弯曲梁开展不同加载速率下的断裂试验,获得其断裂的荷载-裂缝嘴张开口位移曲线及峰值荷载、断裂韧度、临界缝高比增量、弹性模量和柔度系数等断裂参数,结合Pearson相关性检验公式及加载速率效应模型,定量分析初始缝高比、加载速率与断裂参数间的相关性强弱及SCC断裂参数的加载速率效应。结果表明峰值荷载、断裂韧度及弹性模量均存在一定的加载速率效应,柔度系数仅与初始缝高比强相关,弹性模量和断裂韧度是材料的固有属性,不受初始缝高比影响。同时,基于声发射(Acoustic emission,AE)技术对SCC的损伤断裂过程、断裂边界效应及裂缝扩展模式进行分析,结果表明,AE参量能较好地反映混凝土断裂的三阶段特性及边界效应。裂缝的扩展首先以拉伸裂缝为主,剪切裂缝占比随着裂缝扩展过程逐渐增大。      

Effects of fiber orientation on the acoustic emission and fracture characteristics of composite laminates

The effects of fiber orientation on acoustic emission (AE) characteristics have been studied for various composite laminates. Reflection and transmission optical microscopy were used to investigate the damage zone of specimens. AE signals were classified through short time Fourier transform (STFT) as different types: AE signals with a high intensity and high frequency band were due to fiber fracture, while weak AE signals with a low frequency band were due to matrix cracking and/or interfacial cracking. Characteristic feature in the rate of hit-events having high amplitudes showed a procedure of fiber breakages, which expressed the characteristic fracture processes of notched fiber-reinforced plastics with different fiber orientations. As a consequence, the behavior of fracture in the continuous composite laminates could be monitored through nondestructive evaluation (NDE) using the AE technique.     

Acoustic emission and inclusion fracture in 7075 aluminum alloys

For slow crack growth (da/dn 0.1 µm per load cycle) in 7075-T6 aluminum, quantitative agreement was found between the amplitude distribution of burst acoustic emissions and the area size distribution of intermetallic inclusions 10 (µm)² in area as measured on thepolished fracture face. This observation permits the prediction of the amplitude distribution of acoustic emissions due to crack growth in a particular sample of 7075-T6 aluminum directly from a simple, standard metallographic observation performed on the material in question. It was also found that a reduction of the yield stress from that of 7075-T6 aluminum (503 MPa) to that of 7075-0 aluminum (103 MPa) completely eliminated burst acoustic emission activity due to crack advance in the amplitude range studied.     

Acoustic Emission Study of Fatigue Cracks in Materials Used for AVLB

The Armored Vehicle Launch Bridge (AVLB) is subjected to cyclic loading during launching as well as during tank crossings. The cyclic loading causes cracks to initiate in critical bridge components, and then to propagate. Unless these cracks are detected and repaired before they rapidly grow to reach their critical stage of propagation, the failure of bridge components can occur. Three AVLB components, the splice doubler angle, the splice plate, and the bottom chord, are susceptible to fatigue damage. In the present study, laboratory fatigue tests on the materials used for the components, aluminum 2014-T6, aluminum 7050-T765, and ASTM A36 steel, were conducted using the acoustic emission (AE) fatigue crack monitoring technique. A total of fourteen compact-tension specimens were prepared in this study: six aluminum 2014-T6, four aluminum 7050-T76511, and four ASTM A36 steel specimens. The characteristics of AE signals associated with the stress intensity factor, K, were obtained to understand AE behavior corresponding to the fatigue crack growth in the materials. Several AE parameters, such as AE counts, energy, and hits, have been shown to be useful tools for detecting cracks, providing early warnings, and preventing failure of the AVLB structures. A major jump in AEcount rate as well as AE hit rate occurred when K_max reached a value of about 30~MPam (27 ksiin.) for aluminum 2014-T6 specimens and about 50 MPam (46 ksiin.) for aluminum 7050-T76511 specimens. Also, AE source location techniques were able to successfully locate the path ofcrack propagation.     

Cyclic AE count rate and crack growth rate under low cycle fatigue fracture loading

In the low cycle fatigue fracture testing with KS (or JIS) SS41 steel, crack growth rate, AE count rate and J-integral range are measured to get empirical relationships between crack growth rate and J-integral range, AE count rate and J-integral range as well as AE count rate and crack growth rate. All the relationships are shown to be linear on the log—log graphs. It is also shown that the linear relationships can be formulated by using Dunegan's assumption and elastic-plastic fracture mechanics along with the well-known relationships of crack growth rate and J-integral range. It is concluded that the differences between experimental and theoretical values are due to the problem of Dunegan's assumption.     

An investigation of the damage mechanisms and fatigue life diagrams of flax fiber-reinforced polymer laminates

In this paper we investigated the fatigue damage of a unidirectional flax-reinforced epoxy composite using infrared (IR) thermography. Two configurations of flax/epoxy composites layup were studied namely, [0]₁₆ unidirectional ply orientation and [±45]₁₆. The high cycle fatigue strength was determined using a thermographic criterion developed in a previous study. The fatigue limit obtained by the thermographic criterion was confirmed by the results obtained through conventional experimental methods (i.e., Stress level versus Number of cycles to failure). Furthermore, a model for predicting the fatigue life using the IR thermography was evaluated. The model was found to have a good predictive value for the fatigue life. In order to investigate the mechanism of damage initiation in flax/epoxy composites and the damage evolution, during each fatigue test we monitored the crack propagation for a stress level and at different damage stages, a direct correlation between the percentage of cracks and the mean strain was observed.     

Evaluation of in situ fracture toughness of ceramic coatings at elevated temperature by AE inverse analysis

This paper describes acoustic emission (AE) measurement at elevated temperature by laser techniques. AE signals originated from microfracture of Al₂O₃/SUS304 plasma sprayed coatings were detected using a laser interferometer during thermal cycling. The radii of microcracks were evaluated by the inverse analysis of AE signals. Microcrack radii were also studied by the numerical analysis based on the delamination model for coating materials with various fracture toughness and an initial crack size at elevated temperature. In situ fracture toughness for microcracking was evaluated by combining the results of AE inverse analysis with those of numerical analysis. This approach revealed that the in situ toughness of the coatings is 40–50 J/m², consistent with the results of a double cantilever beam test.     

Intralaminar fracture mechanism in unidirectional CFRP composites: Part I: Intralaminar toughness and AE characteristics

Three types of representative carbon fiber reinforced unidirectional composite materials were used and their intralaminar fracture behavior was investigated using the double-cantilever beam specimen with a simultaneous acoustic emission measurement. The intralaminar fracture toughness was evaluated by both the compliance method and energy area method. As a result, it was found that the intralaminar fracture toughness without bridging fibers had a constant value during crack propagation but it increased greatly when bridging fibers were present. The effect of bridging fibers on the intralaminar fracture toughness was estimated quantitatively by cutting the bridging fibers. Distinct differences in load–displacement curves, compliance, crack propagating behavior and acoustic emission signal characteristics between these three types of unidirectional composite materials were observed. It was also found that bridging fiber failure generated relatively large power spectra and contributed to the peak frequencies of 600–700 kHz in the spectrum analysis of acoustic emission (AE) signals. This suggested that the bridging fibers were also an important source of AE signals. Furthermore, a linear relationship between crack length and normalized cumulative AE event count rate was obtained.     

Characterisation of Damaged Tubular Composites by Acoustic Emission,Thermal Diffusivity Mapping and TSR-RGB Projection Technique

An increase in the use of composite materials, owing to improved design and fabrication processes, has led to cost reductions in many industries. Resistance to corrosion, high specific strength, and stiffness are just a few of their many attractive properties. However, damage tolerance remains a major concern in the implementation of composites and uncertainty regarding component lifetimes can lead to over-design and under-use of such materials. A combination of non-destructive evaluation (NDE) and structural health monitoring (SHM) have shown promise in improving confidence by enabling data collection in-situ and in real time. In this work, infrared thermography (IRT) is employed for NDE of tubular composite specimens before and after impact. Four samples are impacted with energies of 5 J, 7.5 J, and 10 J by an un-instrumented falling weight set-up. Acoustic emissions (AE) are monitored using bonded piezoelectric sensors during one of the four impact tests. IRT data is used to generate diffusivity and thermal depth mappings of each sample using the thermographic signal reconstruction (TSR) red green blue (RGB) projection technique. Analysis of AE data alone for a 10 J impact suggest significant damage to the fibres and matrix; this is in good agreement with the generated thermal depth mappings for each sample, which indicate damage through multiple fibre layers. IRT and AE data are correlated and validated by optical micrographs taken along the cross section of damage.     

Fatigue-life prediction of SiC particulate reinforced aluminum alloy 6061 matrix composite using AE stress delay concept

A study of the residual fatigue life prediction of 6061-T6 aluminum matrix composite reinforced with 15 vol % SiC particulates (SiC_p) by using the acoustic emission technique and the stress delay concept has been carried out. Fatigue damages corresponding to 40, 60 and 80% of total fatigue life were stimulated at a cyclic stress amplitude. The specimens with and without fatigue damage were subjected to tensile tests. The acoustic emission activities were monitored during tensile tests. It was found that a lower stress level was required to reach a specified number of cumulative AE events for specimens fatigued to higher percentage of the fatigue life. This stress level is called stress delay. Approximately a linear relation was found between stress delay and fatigue damage. Using the procedure defined in this study, the residual fatigue life can be predicted by testing the specimen in tension and monitoring the AE events. The number of the cumulative AE events increased exponentially with the increase of strain during tensile tests. This exponential increase occurred when the material was in the plastic regime and was attributed mainly to SiC particulate/matrix interface decohesion and linkage of voids. In high cycle fatigue, it was observed that the residual tensile strengths of the material did not change with prior cyclic loading damages since the high cycle fatigue life was dominated by the crack initiation phase.     

Relation of Electromagnetic Emission and Crack Dynamics in Epoxy Resin Materials

Electromagnetic emission (EME) testing and acoustic emission (AE) testing are applied to investigate the failure of a brittle, dielectric material under mechanical load. A setup for three point flexure tests comprising simultaneous monitoring of EME and AE was used to induce fracture of epoxy resin specimens. The influences of the orientation and the distance of the crack surface on the detectable EME signals are the subjects of investigation. As EME sensor a capacitive sensor was used. Tests with an artificial test source are carried out to characterize the system response of the sensor, the attached amplifier and acquisition cards as well as the included bandpass filters. We propose an EME source based on the surface charge density modelled at the position of the fracture plane. Results of finite element method modelling of the EME source are compared to experimental results and show very good agreement. The experimental results show a clear directional character of the emitted electromagnetic field and a strong dependence of the detected signals amplitude on source-sensor distance. A significant influence of the measurement chain on the detected electromagnetic signals bandwidth was found. Furthermore it is shown that the electromagnetic signals consist of three contributions originating from different source mechanisms. These are attributed to the separation and relaxation of charges during crack growth and to the vibration of the charged crack surfaces.     

Acoustic Emission Monitoring the Fatigue Crack Growth in SM50B-Zc Steel

The acoustic emission(AE)characteristicsfrom the fatigue crack propagation in SM50B-Zcsteel were strongly affected by the environment me-dium.The AE feature from the fatigue process bothin air and in 3.5% NaCl aqueous solution mani-fested a periodicity which indicated the fatigue ex-tension was discontinuous.The fatigue striationand secondary cracking were the main AE sourcesduring the fatigue crack growth in air.In contrast,AE during the fatigue crack propagation in 3.5%NaCl solution was released from the intergranularfracture and quasicleavage cracking.