Acoustic emission analysis for failure identification in composite materials
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1 Acoustic emission analysis for failure identification in composite materials Markus G. R. Sause Experimental Physics II Institute of Physics University of Augsburg 1. Motivation 2. Methods of AE analysis 3. Validation of classification procedure 4. Applications 5. Summary 1
2 1. Motivation failure of materials x After x DV y Before t all microscopic failure mechanisms in composites generate acoustic emission Freund et al. J. Appl. Mech-T. ASME (1972) Scruby J. Phys. E: Sci. Instrum (1987) Sause et al. J. Nondest. Eval. 29: (2010) 2
3 1 6.2 m m 1. Motivation failure of fiber reinforced composites fib e r b re a k a g e S p e c im e n 2 S p e c im e n 1 0 in te r-p ly d e la m in a tio n cross-ply stacking Challenges: complex modes of failure scatter of material properties Possibilities: improved failure theories improved testing methods acoustic emission for material research 3
4 1. Motivation failure of fiber reinforced composites Manhattan Bridge Space Shuttle Discovery CFRP structural part monitoring of structure in the field detection of abnormal behaviour indication of imminent failure acoustic emission for monitoring of structural integrity 4
5 2. Methods of AE analysis Amplitude [V] 0.1 AE signal Zeit [µs] Signal prediction Counting Localization Classification Amount Position Type of damage Material analysis 5
6 2. Methods of AE analysis AE source localization A E -s o u rc e t 0 d iffe re n c e in p ro p a g a tio n le n g th t 2 Dt-based localization: uses sensor array attached to specimen calculation of arrival time differences inverse calculation of source position visualization as function of load r S o u rc e r 2 grip region (0,0,0 ) r 1 t 1 force specimen Source density: low medium high 6
7 Intensität Intensity Intensity Intensität Intensity Intensität 2. Methods of AE analysis Identification of failure mechanisms Feature based pattern recognition and numerical validation: feature 1 feature 2 feature Frequenz [khz] Frequenz [khz] 0.10 Frequency [khz] Frequency [khz] Feature Extraction Frequenz [khz] Frequency [khz] feature 2 Definition of features Sause et al. J. Nondest. Eval. 29: (2010) Sause et al. Comp. Sci. Technol (2012) Sause et al. Pat. Rec.Letters 33: (2012) 7
8 Intensität Intensity Intensity Intensität Intensity Intensität 2. Methods of AE analysis Identification of failure mechanisms Feature based pattern recognition and numerical validation: feature 1 feature 2 feature Frequenz [khz] Frequenz [khz] 0.10 Frequency [khz] Frequency [khz] Feature Extraction Frequenz [khz] Frequency [khz] feature 2 Definition of features Application of pattern recognition algorithm Sause et al. J. Nondest. Eval. 29: (2010) Sause et al. Comp. Sci. Technol (2012) Sause et al. Pat. Rec.Letters 33: (2012) 8
9 Intensität Intensity Intensity Intensität Intensity Intensität 2. Methods of AE analysis Identification of failure mechanisms Feature based pattern recognition and numerical validation: feature 1 feature 2 feature Frequenz [khz] Frequenz [khz] 0.10 Frequency [khz] Frequency [khz] Feature Extraction Frequenz [khz] Frequency [khz] feature 2 Definition of features Application of pattern recognition algorithm Numerical validation Sause et al. J. Nondest. Eval. 29: (2010) Sause et al. Comp. Sci. Technol (2012) Sause et al. Pat. Rec.Letters 33: (2012) 9
10 3. Validation of classification procedure Which secondary knowledge can link AE signals and their source? in-situ methods Thermography Digital Image Correlation model predictions single source experiments model composites in-situ CT electromagnetic emission analytical calculations numerical modeling micromechanical experiments online microscopy 10
11 3. Validation of classification procedure FEM modeling of acoustic emission AE source modeling (simple example): force F 2D-plane von Mises stress coordinate system origin 5.2 mm 2 mm a crack growth y z x fixed constraint y x signal detection point explicit modeling of crack growth in material by cohesive zone type approach simultaneous modeling of acoustic signal propagation 11
12 3. Validation of classification procedure FEM modeling of acoustic emission AE source modeling (simple example): radiation radiation crack growth accumulated stress velocity field (near field) velocity field (far field) 12
13 3. Validation of classification procedure FEM modeling of acoustic emission AE source modeling (composite): AE sensors AE source: Matrix cracking t < 5x10-5 s Fiber-PML RVE Composite-PML crack model Fiber breakage t < 5x10-5 s Details of FEM modeling procedure: Sause et al. 19th ICCM, Montreal (2013) Sause et al. J. Nondest. Eval. 29: (2010) Sause et al. J. Acoustic Emission (2010) Sause et al. Composites Part B (2013) Sause J. Acoustic Emission 29 (2012) Sause J. Acoustic Emission 31:1 (2013) Sause et al. Sens. Act. A (2012) Sause et al. 29th EWGAE, Vienna (2010) source modeling signal propagation signal detection 13
14 Partial Power 2 [%] 3. Validation of classification procedure Partial Power 2 [%] Result of forward modeling procedure Comparison between simulation and experiment: Simulation Experiment Matrix crack, all angles (IFF) 60 Matrixcrack (IFF) Interfacial failure (DEF) Fiber breakage (FF) 60 Out-of-plane delamination (DEF) Fiber-Matrix debonding (DEF) Fiber bundle breakage (FF) Single Fiber breakage (FF) source-sensor distance Weighted Peak-Frequency [khz] Weighted Peak-Frequency [khz] similar cluster structures observed for experiment and simulation possibility to correlate experimental signal clusters to respective source mechanisms Model based validation of cluster origins 14
15 force Kraft [N] Akkumulierte number Anzahl of signals AE-Signale 4. Applications short beam shear test force specimen WD sensor F visible F AE AE onset Traversenweg [mm] cross-head displacement [mm] Mechanical parameters: velocity1 mm/min loading till first load drop Acoustic emission: detection using one WD sensor 40dB preamplification 10 MSPs acquisition rate 20 khz 1 MHz bandpass filter 15
16 2.2 m m m m 7 4 m m 4. Applications tensile testing m m [0 /0 /9 0 /0 /0 ] s y m [0 /0 /9 0 /9 0 /0 ] s y m [0 /9 0 /9 0 /9 0 /0 ] s y m 1 6 m m 1 W D -S e n s o r Specimens: Sigratex CE prepreg Cross-ply stacking with additional reinforcements in non-tapered regions m m 2 markers for strain measurement M a rk e r fü r D e h n u n g s m e s s u n g Mechanical parameters: velocity1 mm/min loading till load drop to 40% F max non-contact optical strain measurement K ra ft gripping region S p a n n - b e re ic h Acoustic emission: detection using two WD sensors 40dB preamplification 10 MSPs acquisition rate 20 khz 1 MHz bandpass filter 16
17 stress [MPa] 4. Applications accumulated number of signals acoustic emission recorded during tensile test 1600 Evolution of failure mechanisms: time [s] matrix cracks in off-axis plies Laminate [0/0/90/0/0] sym Matrix Cracking Interfacial failure Fiber breakage Stress-strain curve onset of delamination strain [%] onset of single filament failure 17
18 Stress [MPa] Strain [%] 4. Applications comparison to Puck s failure criteria Comparison to acoustic emission results: Calculated First ply failure Last ply failure Measured Onset Matrix cracking Onset Interfacial failure Onset Fiber breakage Maximum stress Calculated First ply failure Last ply failure Measured Onset Matrix cracking Onset Interfacial failure Onset Fiber breakage Maximum strain [0/0/90/0/0] sym [0/0/90/90/0] sym [0/90/90/90/0] sym [0/0/90/0/0] sym [0/0/90/90/0] sym [0/90/90/90/0] sym onset of first ply failure in good coincidence with onset of matrix cracking and interfacial failure onset of first filament failure preceeds last ply failure systematically 18
19 3-4 m m 4. Applications W D -S e n s o re n H ilfs s e n s o r DCB Double Cantilever Beam 1 C F K -P ro b e 2 3 Source density: R is s s p itz e m m x t 100 s x 60 mm crack progress vs. time pseudo-3d view unequal density of acoustic emission sources during experiment indicates changes in crack growth microscopic origin? 19
20 Akkumulierte number Anzahl of der signals SE-Signale [#] force Kraft [N] relative Relative accumulated akkumulierte signal Signalamplitude amplitudes [%] Hexcel RTM6= 168 [J/m²] HexPly914= 103[J/m²] 4. Applications DCB Double Cantilever Beam cross-head Traversenweg displacement [mm] [mm] matrix Matrixrisse cracking interfacial Interfaceversagen failure 2000 fiber Faserbruch breakage force-disp. Kraft-Weg Kurve curve 1500 SE-Ersteinsatz AE onset Matrixriss matrix cracking Lineare linear regression Regression Interfaceversagen interfacial failure Lineare linear regression Regression Faserbruch fiber breakage time Zeit [s] [s] systematic relationship between contributions of different failure mechanisms and the resulting fracture toughness values confirmed by microscopy investigations of fracture surface G G Ic - Wert [J/m²] Ic -value [J/m²] 20
21 5. Summary Summary: acoustic emission allows for 1. localization of active damage in composite materials 2. distinction of different failure types in composite materials acoustic emission allows for a variety of possibilities to diagnose and understand damage progression in fiber reinforced composites and hybrids other applications adressed in the past comprise bondings, ENF, NOLrings, CT-specimens, SENB-specimens, DENT-specimens, TDCBspecimens, peel-tests, fiber fragmentation, single filament testing, coating integrity, sandwich structures, burst pressure tests, windmill blades, 21
22 Acknowledgments: Dr. G. Obermeier Dr.-Ing. A.-M. Zelenyak M. Sc. T. Guglhör M. Sc. S. Kalafat M. Sc. A. Monden M. Sc. S. Richler M. Sc. E. Laukmanis Dipl. Phys. S. Gade B. Sc. F. Staab B. Sc. U. Buchner B. Sc. N. Anderle B. Sc. N. Schorer Thank you for your attention! S. Bessel Dipl.Ing. (FH) S. Schmitt 22
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