Intrinsic CFRP-metal-hybrids with rubber interface for the improvement of the damping behaviour

This paper presents an integrated passive damping approach in hybrid metal-CFRP parts for structural applications. In this concept a viscoelastic material is embedded in the joint zone of the hybrid component. To examine the connection strength single-lap-joint specimens were produced and tested and the influence of the used material combinations, different surface structures, and different process parameters i.e. the moment of cross-linking were evaluated. Afterwards, the metal-CFRP hybrids were tested in quasi-static tests to assess their connection strength and failure behaviour. Dynamic cyclic tensile tests with step-wise increased loading conditions were performed to determine the specimens damping behaviour and to estimate their fatigue performance. Finally, these results are compared to a state of the art metal-CFRP hybrid with rivets connecting both materials.     

钢轨表面缺陷漏磁检测的三维磁场分析

漏磁检测技术通常测量垂直和平行于缺陷表面的漏磁场分量,来实现对缺陷的定量分析。然而,对于钢轨表面的复杂裂纹,传统的方法很难准确检测。为了克服这种检测方法存在的不足,采用三维磁场测量方法以及有限元法对缺陷漏磁场的三维分布情况进行了分析。在此基础上设计了一套适合钢轨表面缺陷检测的三维漏磁检测系统,并对人工缺陷样例进行了检测。结果表明,漏磁信号垂直分量包含重要的缺陷信息,特别是对于与钢轨走向不垂直的缺陷。     

Analysis and specification of the crash behaviour of plastics/metal-hybrid composites by experimental and numerical methods

Plastics materials are nowadays used in many structural applications for the substitution of metals with respect to weight reduction. In order to utilize the high freedom of design and the light-weight potential of plastics materials in crash-relevant structural parts, so-called hybrid composites which combine the high rigidity and strength of steel with the advantages of plastics materials are investigated in the outlined research. Thereby, the joining of both materials as well as the design by means of numerical methods such as the finite element analysis (FEA) are challenges which have to be met. A new approach in joining is based on the modified arc welding process where metal pin structures are formed in one working step and subsequently welded onto the surface. The pins are formed with ball-shaped, cylindrical or spiky ends and produced directly from the welding wire without requiring additional pre-fabricated components such as studs or similar. This allows the small-scale surface structuring of metal components that can be adapted optimally for a form fit on the respective plastics structure. Subsequently, injection molding is used for the application of the plastics material onto the pin-structured metal part in order to generate a positive fit between metal and plastics in an intrinsic joining process. An additional joining process, which is carried out after injection molding, is not required. Within the framework of the research presented, comprehensive mechanical tests are presented to illustrate the suitability of pin-structured metal-hybrid composites in crash applications. In comparison to structures which are in particular exposed to static loads and therefore designed to exhibit maximum component strength, crash applications are designed to fail in a continuous process to achieve maximum energy consumption. The outlined research illustrates the enhanced failure behavior of pin-structured plastics/metal-hybrid composites and the increased energy consumption under impact loading. Moreover, a comparison between pin structuring and laser structuring with regard to the obtainable mechanical properties under impact loading is given. Concluding, the current potential and weak points in the simulation of plastics/metal-hybrid structures using FEA is presented and discussed.     

漏磁检测信号轴向分量和径向分量的选择

缺陷漏磁场的径向分量和轴向分量是漏磁检测中经常检测的物理量,两者之间如何选择,至今尚无定论。采用等效面偶极子模型分析了缺陷漏磁场的空间分布特点,解释了径向分量比轴向分量衰减更快的原因。结合有限元方法,研究了不同深度、宽度的二维矩形槽和不同倾角的梯形槽缺陷的漏磁场分布,分析了径向分量与轴向分量的变化特点,总结了缺陷参数变化时临界点的变化趋势。从探头设计的角度,考察了探头提离值以及缺陷参数对缺陷漏磁场信号轴向和径向分量幅值的影响,提出利用临界点作为检测分量的选取原则。     

Magnet–Solenoid type active vibrometer for non-destructive testing of electric power transmission line insulators

An active vibrometer used for the non-destructive test of electric power transmission line insulators has been developed. With a permanent magnet and a couple of coils, the vibrometer exerts impact force to a test object and in turn picks up the vibration of the object. The resonance frequencies with the amplitudes obtained from the vibrometer are used as a basis for detecting defects in the object. The vibrometer is controlled by an electronic device designed to facilitate the fully automated testing process with consistent repeatability and reliability which are essential to the non-destructive test. The vibrometer is expected to be applied to the wide area of defect detection including the classification of mechanical parts in production and inspection processes.     

Non-destructive evaluation of brazed joints between cooling tube and heat sink by IR thermography and its verification using FE analysis

A non-destructive testing (NDT) and evaluation technique for the assessment of defects in brazed joints is presented in this paper. It is based on the analysis of infrared thermography (IRT) images, which produces two-dimensional temperature fingerprints to qualitatively see the invisible defects. This feature is fruitfully exploited to detect the significant faults in the brazed joints between the cooling tube and heat sink of the plasma facing components (PFC). Three-dimensional finite element (FE) analyses have been performed to simulate the brazing defects. Additional investigations like non-destructive radiographic test also confirms the experimental observations obtained from IRT.     

Investigation of the coating thickness of plasma-transferred arc deposition welded and cross wedge rolled hybrid parts

Most of today’s technical parts and components are made of monolithic materials. These mono-material components produced in established production processes reach their limits due to their respective material characteristics. Thus, a significant increase in production quality and efficiency can only be achieved by combining different materials in one part. Bulk forming of previously joined semi-finished products to net shape hybrid components that consist of two different materials is a promising method to produce parts with locally optimized characteristics. This new production process chain offers a number of advantages compared to conventional manufacturing technologies. Examples are the production of specific load-adapted forged parts with a high level of material utilization, an improvement of the joining zone caused by the following forming process and an easy to implement joining process due to the simple geometries of the semi-finished products. This paper describes the production process of hybrid steel parts, produced by combining a plasma-transferred arc deposition welding process with a subsequent cross wedge rolling process. This innovative process chain enables the production of hybrid parts. To evaluate the developed process chain, coating thickness of the billet is analysed before and after cross wedge rolling. It could be shown, that the forming process leads to an improvement of the coating, meaning a more homogeneous distribution along the main axis.     

声-固耦合模型下自适应高维特征焊缝缺陷超声检测

针对焊缝缺陷种类识别精度有待提高的问题,提出了一种将随机森林与变分模态分解相结合的算法,以结合二者的自适应特征提取能力及对于高维特征的强适应特性。利用多物理场仿真软件建立含缺陷焊缝的声-固耦合模型,进行超声波无损检测仿真,得到含缺陷超声回波信号。利用变分模态分解求出其各IMF能量分布系数,并以其作为特征向量建立随机森林模型,进行焊缝缺陷识别。结果表明,利用该方法提取的缺陷回波信号特征能有效表征焊缝缺陷,以其建立随机森林模型可以对其进行准确识别。     

Influence of different alloying elements on the intermetallic phase seam thickness of compound forged steel-aluminum parts

In times of increasing energy costs automotive light weight construction is gaining more importance. Thus, attempts have been made to replace steel components with parts made of aluminum alloys. This, however, often involves the deterioration of important component properties and impedes material substitution in mechanically high-stressed parts like gear components. Due to this, the attempt to design load-optimized parts with hybrid structure which correspond to the requirements of structural light weight construction is made. The production of hybrid compounds by forging is a promising method to manufacture functional parts by applying resource-saving process steps. The aim of the presented research is to determine the optimal production parameters for compound forging. To characterize the component quality it is necessary to investigate the factors influencing the joining zone.     

Dual EMAT and PEC non-contact probe: applications to defect testing

For many non-destructive testing (NDT) applications, more information and greater reliability can be gained by using different techniques for defect detection, especially when the methods are particularly sensitive to different types of defects. However, this will often lead to a much longer and more expensive test and is not always practical due to time and cost constraints. We have previously discussed initial experiments using a new dual-probe combining electromagnetic acoustic transducers (EMATs) generating and detecting ultrasonic surface waves, and a pulsed eddy current (PEC) sensor [1]. This enables more reliable detection and sizing of surface and near-surface defects, with a reduced testing time compared to using two NDT techniques separately. In this paper, we present experiments using the dual-probe on samples which are more representative of real defects, for example testing for surface defects in rails. Several aluminium calibration samples containing closely spaced and angled slots have been measured, in addition to rail samples containing manufactured and real defects. The benefits of using the dual-probe are discussed.     

TA15钛合金激光熔化沉积制件超声相控阵检测

为了确保激光增材制件的质量安全,对其进行可靠的无损检测与评价尤为重要。 针对 TA15 钛合金激光熔化沉积制件,使用常规超声以及超声相控阵检测技术对其内部缺陷进行检测,重点研究了激光增材制件内部缺陷的超声检测特性以及超声相控阵检测技术在增材制件上的应用优势。 使用激光熔化沉积技术制备了含有熔合不良缺陷的试验样件,从 XYZ 3 个方向分别对样件进行了全面检测。 结果表明,激光增材制件内部的缺陷具有明显的方向性,因此, 为了确保激光增材制件检测结果可靠,应从 XYZ 3 个方向分别进行全面检测。 相比与常规超声检测,超声相控阵检测技术大大提高了检测效率,能够直接成像缺陷的轮廓边界,降低了技术依赖性及人工疲劳性,针对大型增材制件的检测需求具有广阔的应用前景。     

Application of ultrasonic guided waves for non-destructive testing of defective CFRP rods with multiple delaminations

One of the most important parts of gliders is a lightweight longeron reinforcement made of carbon fibre reinforced plastic (CFRP) rods. During manufacturing, in order to build the arbitrary spar profile, these small diameter (few millimetres) rods are glued together into epoxy filled matrix. Still, defects present in the rods, such as break of fibres, multiple delaminations due to lack of bonding and reduction in density affect construction strength markedly and are extremely complicated to eliminate. Therefore, appropriate non-destructive testing techniques intended for carbon fibre rods should be applied prior to gluing them together.The aim of the present paper is to analyse development possibilities of NDT technique based on application of ultrasonic guided waves and intended for CFRP rods that are used for aerospace applications and are defective with multiple delaminations.The regularities of ultrasonic guided wave propagation in a defective CFRP circular-shape rod with multiple delaminations have been investigated using 3D numerical simulations, finite difference and finite element models. The corresponding experiments have been conducted as well. Based on leaky wave suppression over a defective region due to the weak vertical component of particle displacements, the mechanism of guided wave interaction with the region of multiple delaminations is explained from the ultrasonic NDT viewpoint.     

热障涂层无损检测技术研究进展

为提高发动机的涡轮前温度和热端部件服役寿命,热障涂层（TBCs）被广泛应用于燃气涡轮发动机。热障涂层具有多相、多界面和非均质特性,且其服役工况恶劣复杂。寻找一种可以表征涂层显微组织、缺陷、热物性、应力等反映涂层质量和剩余寿命的无损检测方法,对发动机的热端部件安全性和可靠性至关重要。文中综述了超声检测技术（UT）、声发射技术（AE）、红外热成像技术（IRT）、阻抗谱技术（IS）和光激发荧光压电光谱技术（PLPS）的原理以及其在热障涂层无损检测中的研究应用,并详细介绍了太赫兹时域光谱（THz-TDS）技术及其在热障涂层中的应用。最后总结了上述无损检测方法的检测能力,并对热障涂层无损检测方法进行展望。     

Basic study on the process combination of deposition welding and subsequent hot bulk forming

Today most technical parts and components are made of monolithic materials. Nevertheless, the previously used monolithic materials reach their technological and constructive limits, so that an improvement of the component properties can be realized by hybrid parts. Forging of previously joined semi-finished products to net shape hybrid components is a promising method to produce functional adapted parts in a few process steps. This new process chain offers a number of advantages compared to other manufacturing technologies. Examples are the production of specific load-adapted forging parts with a high level of material utilization, an improvement of the joining zone caused by the followed forming process and an easy to implement joining process because of the simple geometries of the semi-finished products. This paper describes the production process of hybrid steel parts, which are produced by a combination of a deposition welding process with a subsequent hot forging (upsetting) or cross-wedge-rolling. It could be shown that the innovative process chain enables the production of hybrid parts whereby the forging processes lead to an improvement of the mechanical properties of the laser deposited material.     

A new non-contacting non-destructive testing method for defect detection in concrete

A new non-destructive testing (NDT) method for defect detection in concrete structures is presented. The method is based on the dynamic response of flawed concrete structures subjected to impact loading. Conversely to similar NDT techniques, such as the impact-echo method, the present method uses non-contacting devices for both impact generation (a shock tube producing shock waves) and response monitoring (laser vibrometers measuring concrete surface velocity). Experimental and numerical (finite element) studies have been carried out for concrete specimens containing artificial defects (penny-shaped cracks parallel to the free surface) with varying length and depth. According to the experimental and numerical results, it appears that the present method enables an effective detection of defects, particularly in the range of shallow defects.     

Ultrasonic and structural characterization of anisotropic austenitic stainless steel welds: Towards a higher reliability in ultrasonic non-destructive testing

The non-destructive testing of austenitic stainless steel welds of the primary coolant piping system is a significant problem for the nuclear industry. Ultrasonic techniques would be very helpful to detect, locate and size potential defects. Unfortunately, austenitic welds are coarse-grained, heterogeneous and anisotropic. This leads to aberration and scattering of the ultrasonic waves. In this paper, we present several experimental results of ultrasonic testing of two austenitic welds exhibiting high anisotropy. In order to explain the observed display of wave propagation phenomena such as beam deviation, we use finite element modeling. The modeling is associated with a complete characterization of the inspected welds. Two essential characteristics of the welds are determined: the average elastic constants of the weld and the grain orientations. The capability of the model is illustrated in different testing configurations. This work associating structural characterization and modeling shows that a better understanding of the phenomena of ultrasonic propagation should allow the interpretation and reliability of the industrial inspections of heterogeneous anisotropic welds to be improved.     

Characterization of sheet metal components by using an upsetting test with miniaturized cylindrical specimen

Especially for safety-relevant components local characterization of the mechanical properties is necessary for product testing. For sheet metal parts with a complicated geometry conventional specimens for standardized tests cannot be extracted due to size limitations. Thus, a novel extraction procedure of miniaturized upsetting specimens is investigated. Taking a miniaturized upsetting specimen out of the sheet component allows for the first time the characterization of sheet metals in a standardized upsetting test under uniaxial compression stresses. Furthermore, this enables the analysis of strain hardening behavior of components and a direct validation of finite element simulations based on the true stress.     

基于超声无损检测的扩散连接界面缺陷尺寸评估

针对扩散连接界面缺陷的无损检测问题,开展了人工缺陷试样的水浸超声检测试验研究,提出了扩散连接界面缺陷超声响应模型,开发了一种通过超声检测评估界面缺陷厚向尺寸的检测手段. 首先利用扩散连接的方法制备了带有人工缺陷扩散连接试样,采用30 MHz的入射波频率,对试样进行水浸超声无损检测. 基于超声无损检测原理提出了未焊合缺陷的超声响应模型,引入扩散连接界面劲度系数K作为桥梁建立起超声反射波反射率与界面缺陷尺寸之间的联系. 通过特定检测位置的超声反射波数据和实际微观缺陷尺寸数据拟合确定超声响应模型常数,进而实现基于超声无损检测的界面缺陷厚向尺寸评估. 结果表明,传统超声C扫描一般只是定性地反映缺陷存在与否,而厚向尺寸评估方法的提出在一定程度上为超声C扫描做了补充,有助于缺陷尺寸的定量检测,实现缺陷危害等级的评估.     

FE approach and experiments for an axisymmetric micro-yoke part forming using grain element and grain boundary element

Until present, an axisymmetric yoke part of electro-magnetic micro-speaker/receiver had manufactured by machining through the material’s removal. However, this machining process have some problems such as long production time, high precision of tool and costs. In this study, a program based on finite element method developed to establish milli-structure forming technology for micro-yoke component, one of the key parts in the multi-functioned micro-speaker/receiver. This developed program is applied for the milli-part forming in order to replace the machining process of micro-yoke. A new numerical approach is proposed to simulate intergranular milli-structure in forming the miniature yoke, in which grain elements and grain boundary elements are introduced. The results of the finite element analysis for micro-yoke part are confirmed by a series of experiments.     

圆筒形容器漏磁内检测ANSYS仿真分析与试验

针对石油化工行业圆筒形容器特点，将漏磁检测应用于圆筒形容器检测上。应用ANSYS软件对圆筒形容器漏磁内检测进行仿真分析，分析了缺陷尺寸、容器壁厚、内、外壁缺陷等影响缺陷漏磁信号的因素；在此基础上对圆筒形容器漏磁内检测进行试验研究，对部分分析结果进行试验验证，验证了有限元分析结果的正确性。