Probabilistic Approach for Nondestructive Detection of Fatigue Crack Initiation and Sizing
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Published
Nov 13, 2020
Azadeh Keshtgar
Mohammad Modarres
Abstract
Early detection of a growing crack is one of the concerns in structural integrity and can be used to predict the remaining useful life of a structure. Acoustic Emission (AE) is a nondestructive
testing method with potential applications for locating and monitoring fatigue cracks. A novel AE signal analysis approach is proposed in this paper to detect crack initiation and assess small crack growth behavior. A probabilistic AE-based model for small fatigue cracks was developed and the uncertainties of the model were estimated. The outcome of this research can be used to evaluate the integrity of structures and assess structural health by estimating the probability density function of the length of detected cracks. This paper discusses the methodology used, experimental approach, results obtained and predictive models developed.
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Keywords
Structural Integrity, acoustic emission, fatigue, Reliability Assessment, uncertainty analysis, Crack initiation
References
Anderson, T., (1995). Fracture Mechanics: Fundamentals and Applications. Boca Raton: Boca CRC Press.
ASTM E466 (2012). Standard practice for conducting force controlled constant amplitude axial fatigue tests of metallic materials. ASTM International, vol. i.
Beattie, A. G. (1983). Acoustic emission, principles and instrumentation. Journal of Acoustic Emission, 2, 95–128.
Berkovits, A. & Fang, D. (1995). Study of fatigue crack characteristics by acoustic emission. Engineering Fracture Mechanics, 51(3), 401–416.
Bhattacharya B. & Ellingwood, B. (1998). Continum damage mechanics analysis of fatigue crack initiation, Journal of Fatigue, 20(9), 631–639.
Capek J., Mathis, K., Clausen, B., Straska, J., Beran, P. and Lukas, P. (2014). Study of the loading mode dependence of the twinning in random textured cast magnesium by acoustic emission and neutron diffraction methods. Materials Science & Engineering, 602, 25-32.
Chaswal, V., Sasikala, G., Ray, S. K., Mannan, S. L. & Raj, B. (2005). Fatigue crack growth mechanism in aged 9Cr–1Mo steel: threshold and Paris regimes. Materials Science and Engineering: A, 395(1–2), 251–264.
Chiachio, J., Chiachio, M., Sankararaman, S., Saxena, A. & Goebel, K. (2015). Condition-based prediction of time dependent reliability in composites. Reliab Eng Syst Safe, 142: 134–147.
Chiachio, M., Chiachio, J., Rus, G. & Beck, J. L. (2014). Predicting fatigue damage in composites: a Bayesian framework. Struct Saf, 51, 57–68.
Eberhardt, E., Stead, D., Stimpson, B. & Read, R. S. (1997). Changes in Acoustic event properties with progressive fracture damage. International journal of Rock Mech. & Min. Science, 34(71), 3–4.
Elforjani M. & Mba, D. (2009). Natural mechanical degradation measurements in slow speed bearings. Engineering Failure Analysis, 16(1), 521–532.
Forth, S. C., Newman, J. C. & Forman, R. G. (2005). Evaluation of Fatigue Crack Thresholds Using Various Experimental Methods. Journal of ASTM International, 2(6), 1–16.
Georgiou, G. A. (2006). Probability of Detection (PoD) curves: Derivation, applications and limitations. Jacobi Consulting Limited, Research Report 454.
Han Z., Luo, H., Sun, C., Li, J., Papaelias, M. & Davis, C. (2014). Acoustic emission study of fatigue crack propagation in extruded AZ31 magnesium alloy. Materials Science & Engineering, 597, 270-278.
Iyyer, N., Sarkar, S., Merrill, R. & Phan, N. (2007). Aircraft life management using crack initiation and crack growth models – P-3C Aircraft experience. International Journal of Fatigue, 29(9–11), 584–1607.
Kappatos, V. & Dermatas, E. (2007). Crack detection in noisy environment including raining conditions. Aircraft Engineering and Aerospace Technology, 79(2),163–169.
Keshtgar, A. & Modarress, M. (2013). Acoustic Emission- Based Fatigue Crack Growth Prediction. Reliability and Maintainability Symposium (1-5), Jan. 28-31, Orlando, FL.
Künkler, B, Düber,O, Köster, P, Krupp, U, Fritzen, C. P., and Christ, H. J. (2008). Modelling of short crack propagation–Transition from stage I to stage II. Engineering Fracture Mechanics, 75(3–4), 715–725.
Larsen, J. M. & Allison, J. E. (1992). Small Crack Test Methods. American Society for Testing and Materials.
Marquez, J. G. M. & Olivares, J. L. (1987). A study of crack initiation and propagation in Ni-Cr thermally sprayed coatings using Acoustic Emission techniques. Thin Solid Films, 153, 243–252.
Mazal, P. Vlasic, F. & Koula, V. (2015). Use of acoustic emission method for identification of fatigue microcracks creation. Procedia Engineering, 133, 379-388.
McDowell, D. L. (1997). An engineering model for propagation of small cracks in fatigue. Engineering Fracture Mechanics, 56(3), 357–377.
Miller, R. K., Hill, E. V. K. & Moore, P. O. (2005). Acoustic Emission Testing. Nondestructive Testing Handbook, ASNT.
Morton, T. M., Harrington, R. M. & Bjeletich, J. G. (1973). Acoustic Emission of fatigue crack growth. Engineering Fracture Mechanics, 5, 691–697.
Ontiveros, V., Cartillier, A. & Modarres, M. (2010) An Integrated Methodology for Assessing Fire Simulation Code Uncertainty. Nuclear Science and Engineering, 166(3), 179-201.
Papazian, J. M., Anagnostou, E. L., Engel, S. J., Hoitsma, D., Madsen, J., Silberstein, R. P., Welsh, G. & Whiteside, J. B. (2009). A structural integrity prognosis system. Engineering Fracture Mechanics, 76(5), 620–632.
Pearson, S. (1975). Initiation of fatigue cracks in commercial aluminium alloys and the subsequent propagation of very short cracks. Engineering Fracture Mechanics, 7, 235–247.
Physical Acoustic Corporation (2007). AEwin Software User’s Manual, Princeton Junction, NJ.
Rabiei, M. & Modarress, M. (2013). Quantitative methods for structural health management using in situ acoustic emission monitoring. International Journal of Fatigue, 49, 81-89.
Rahman, Z., Ohba, H., Yoshioka, T. & Yamamoto, T. (2009). Incipient damage detection and its propagation monitoring of rolling contact fatigue by acoustic emission. Tribology International, vol. 42, no. 6, pp. 807–815, Jun. 2009.
Roberts, T. M. & Talebzadeh, M. (2003). Fatigue life prediction based on crack propagation and acoustic emission count rates. Journal of Constructional Steel Research, 59(6), 679–694.
Sankararaman, S. & Mahadevan, S., (2015). Statistical Approach to Structural Damage Diagnosis under uncertainty. Emerging Design solutions in Structural Health Monitoring Systems,153-169.
Shyam, A., Allison, J. & Jones, J. (2005). A small fatigue crack growth relationship and its application to cast aluminum. Acta Materialia, 53(5), 1499–1509.
Vanniamparambil, P. A. Guclu, U. and. Kontsos A. (2015). Identification of crack initiation in aluminum alloys using acoustic emission. Experimental Mechanics, 55(5),837–850.
Wang, Z. F. , Li, J., Ke, W. and Zhu, Z. (1992). Acoustic emission monitoring of fatigue crack closure. Scripta Metallurgica et Materialia, 27(12), 1691–1694.
ASTM E466 (2012). Standard practice for conducting force controlled constant amplitude axial fatigue tests of metallic materials. ASTM International, vol. i.
Beattie, A. G. (1983). Acoustic emission, principles and instrumentation. Journal of Acoustic Emission, 2, 95–128.
Berkovits, A. & Fang, D. (1995). Study of fatigue crack characteristics by acoustic emission. Engineering Fracture Mechanics, 51(3), 401–416.
Bhattacharya B. & Ellingwood, B. (1998). Continum damage mechanics analysis of fatigue crack initiation, Journal of Fatigue, 20(9), 631–639.
Capek J., Mathis, K., Clausen, B., Straska, J., Beran, P. and Lukas, P. (2014). Study of the loading mode dependence of the twinning in random textured cast magnesium by acoustic emission and neutron diffraction methods. Materials Science & Engineering, 602, 25-32.
Chaswal, V., Sasikala, G., Ray, S. K., Mannan, S. L. & Raj, B. (2005). Fatigue crack growth mechanism in aged 9Cr–1Mo steel: threshold and Paris regimes. Materials Science and Engineering: A, 395(1–2), 251–264.
Chiachio, J., Chiachio, M., Sankararaman, S., Saxena, A. & Goebel, K. (2015). Condition-based prediction of time dependent reliability in composites. Reliab Eng Syst Safe, 142: 134–147.
Chiachio, M., Chiachio, J., Rus, G. & Beck, J. L. (2014). Predicting fatigue damage in composites: a Bayesian framework. Struct Saf, 51, 57–68.
Eberhardt, E., Stead, D., Stimpson, B. & Read, R. S. (1997). Changes in Acoustic event properties with progressive fracture damage. International journal of Rock Mech. & Min. Science, 34(71), 3–4.
Elforjani M. & Mba, D. (2009). Natural mechanical degradation measurements in slow speed bearings. Engineering Failure Analysis, 16(1), 521–532.
Forth, S. C., Newman, J. C. & Forman, R. G. (2005). Evaluation of Fatigue Crack Thresholds Using Various Experimental Methods. Journal of ASTM International, 2(6), 1–16.
Georgiou, G. A. (2006). Probability of Detection (PoD) curves: Derivation, applications and limitations. Jacobi Consulting Limited, Research Report 454.
Han Z., Luo, H., Sun, C., Li, J., Papaelias, M. & Davis, C. (2014). Acoustic emission study of fatigue crack propagation in extruded AZ31 magnesium alloy. Materials Science & Engineering, 597, 270-278.
Iyyer, N., Sarkar, S., Merrill, R. & Phan, N. (2007). Aircraft life management using crack initiation and crack growth models – P-3C Aircraft experience. International Journal of Fatigue, 29(9–11), 584–1607.
Kappatos, V. & Dermatas, E. (2007). Crack detection in noisy environment including raining conditions. Aircraft Engineering and Aerospace Technology, 79(2),163–169.
Keshtgar, A. & Modarress, M. (2013). Acoustic Emission- Based Fatigue Crack Growth Prediction. Reliability and Maintainability Symposium (1-5), Jan. 28-31, Orlando, FL.
Künkler, B, Düber,O, Köster, P, Krupp, U, Fritzen, C. P., and Christ, H. J. (2008). Modelling of short crack propagation–Transition from stage I to stage II. Engineering Fracture Mechanics, 75(3–4), 715–725.
Larsen, J. M. & Allison, J. E. (1992). Small Crack Test Methods. American Society for Testing and Materials.
Marquez, J. G. M. & Olivares, J. L. (1987). A study of crack initiation and propagation in Ni-Cr thermally sprayed coatings using Acoustic Emission techniques. Thin Solid Films, 153, 243–252.
Mazal, P. Vlasic, F. & Koula, V. (2015). Use of acoustic emission method for identification of fatigue microcracks creation. Procedia Engineering, 133, 379-388.
McDowell, D. L. (1997). An engineering model for propagation of small cracks in fatigue. Engineering Fracture Mechanics, 56(3), 357–377.
Miller, R. K., Hill, E. V. K. & Moore, P. O. (2005). Acoustic Emission Testing. Nondestructive Testing Handbook, ASNT.
Morton, T. M., Harrington, R. M. & Bjeletich, J. G. (1973). Acoustic Emission of fatigue crack growth. Engineering Fracture Mechanics, 5, 691–697.
Ontiveros, V., Cartillier, A. & Modarres, M. (2010) An Integrated Methodology for Assessing Fire Simulation Code Uncertainty. Nuclear Science and Engineering, 166(3), 179-201.
Papazian, J. M., Anagnostou, E. L., Engel, S. J., Hoitsma, D., Madsen, J., Silberstein, R. P., Welsh, G. & Whiteside, J. B. (2009). A structural integrity prognosis system. Engineering Fracture Mechanics, 76(5), 620–632.
Pearson, S. (1975). Initiation of fatigue cracks in commercial aluminium alloys and the subsequent propagation of very short cracks. Engineering Fracture Mechanics, 7, 235–247.
Physical Acoustic Corporation (2007). AEwin Software User’s Manual, Princeton Junction, NJ.
Rabiei, M. & Modarress, M. (2013). Quantitative methods for structural health management using in situ acoustic emission monitoring. International Journal of Fatigue, 49, 81-89.
Rahman, Z., Ohba, H., Yoshioka, T. & Yamamoto, T. (2009). Incipient damage detection and its propagation monitoring of rolling contact fatigue by acoustic emission. Tribology International, vol. 42, no. 6, pp. 807–815, Jun. 2009.
Roberts, T. M. & Talebzadeh, M. (2003). Fatigue life prediction based on crack propagation and acoustic emission count rates. Journal of Constructional Steel Research, 59(6), 679–694.
Sankararaman, S. & Mahadevan, S., (2015). Statistical Approach to Structural Damage Diagnosis under uncertainty. Emerging Design solutions in Structural Health Monitoring Systems,153-169.
Shyam, A., Allison, J. & Jones, J. (2005). A small fatigue crack growth relationship and its application to cast aluminum. Acta Materialia, 53(5), 1499–1509.
Vanniamparambil, P. A. Guclu, U. and. Kontsos A. (2015). Identification of crack initiation in aluminum alloys using acoustic emission. Experimental Mechanics, 55(5),837–850.
Wang, Z. F. , Li, J., Ke, W. and Zhu, Z. (1992). Acoustic emission monitoring of fatigue crack closure. Scripta Metallurgica et Materialia, 27(12), 1691–1694.
Section
Technical Papers