Rolling contact fatigue failures in silicon nitride and their detection

The project investigates the feasibility of using sensor-based detection and processing systems to provide a reliable means of monitoring rolling contact fatigue (RCF) wear failures of silicon nitride in hybrid bearings. To fulfil this investigation, a decision was made early in the project to perform a series of hybrid rolling wear tests using a twin disc machine modified for use on hybrid bearing elements.The initial part of the thesis reviews the current understanding of the general wear mechanisms and RCF with a specific focus to determine the appropriate methods for their detection in hybrid bearings. The study focusses on vibration, electrostatic and acoustic emission (AE) techniques and reviews their associated sensing technologies currently deployed with a view of adapting them for use in hybrids. To provide a basis for the adaptation, an understanding of the current sensor data enhancement and feature extraction methods is presented based on a literature review.The second part describes the test equipment, its modifications and instrumentation required to capture and process the vibration, electrostatic and AE signals generated in hybrid elements. These were identified in an initial feasibility test performed on a standard twin disc machine. After a detailed description of the resulting equipment, the thesis describes the calibration tests aimed to provide base data for the development of the signal processing methods.The development of the signal processing techniques is described in detail for each of the sensor types. Time synchronous averaging (TSA) technique is used to identify the location of the signal sources along the surfaces of the specimens and the signals are enhanced by additional filtering techniques.The next part of the thesis describes the main hybrid rolling wear tests; it details the selection of the run parameters and the samples seeded with surface cracks to cover a variety of situations, the method of execution of each test run, and the techniques to analyse the results.The research establishes that two RCF fault types are produced in the silicon nitride rolling element reflecting essentially different mechanisms in their distinct and separate development; i) cracks, progressing into depth and denoted in this study as C-/Ring crack Complex (CRC) and ii) Flaking, progressing primarily on the surface by spalls. Additionally and not reported in the literature, an advanced stage of the CRC fault type composed of multiple and extensive c-cracks is interpreted as the result of induced sliding in these runs. In general, having reached an advanced stage, both CRC and Flaking faults produce significant wear in the steel counterface through abrasion, plastic deformation or 3-body abrasion in at least three possible ways, all of which are described in details

Recent Advances and Applications of Machine Learning in Metal Forming Processes

Machine learning (ML) technologies are emerging in Mechanical Engineering, driven by the increasing availability of datasets, coupled with the exponential growth in computer performance. In fact, there has been a growing interest in evaluating the capabilities of ML algorithms to approach topics related to metal forming processes, such as: Classification, detection and prediction of forming defects; Material parameters identification; Material modelling; Process classification and selection; Process design and optimization. The purpose of this Special Issue is to disseminate state-of-the-art ML applications in metal forming processes, covering 10 papers about the abovementioned and related topics

Recent advances and applications of machine learning in metal forming processes

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Development of a guided wave EMAT online inspection system for Al/Al-Sn/Al/steel and CuSn/steel bimetal strip bond quality control used in the automotive industry

Cold roll bonded (CRB) Al/Al-Sn/Al/steel and sintered CuSnNi/steel bimetal strips are used in the automotive industry for the manufacture of engine bearings, bushes and thrust washers. Any defects such as delamination or porosity that occur in bimetal strips during manufacturing can cause problems at downstream production steps and if they remain undetected, could result in components failing in the field, which is a significant business risk.;One way to reduce this business risk is to install a final inspection system on a continuous production line as the strip passes a fixed inspection point. In process control this could alert the operators to reject defective material and correct process parameters when the defect occurs. As this system requires 100% volumetric inspection, installing it has its challenges due to the harsh manufacturing environment in which the strip moves at up to 20 m/min in the processing lines at room temperature.;A literature review and feasibility study on different non-destructive testing (NDT) techniques to inspect bond quality of CRBed Al/Al-Sn/Al/steel bimetal strips was conducted to assess technologies that could be developed for serial inspection. Guided waves generated using Electromagnetic Acoustic Transducers (EMATs) was identified as best suited for this application. Since this technology was not available off-the-shelf, significant research and experimental work was carried out to develop an automated prototype system.;The system was successfully installed at a strip processing line and demonstrated the online bond inspection capability for Al/Al-Sn/Al/steel and CuSnNi/steel bimetal strips, which is the main achievement of this EngD project. For CuSnNi/steel strips, causes of defects and preventative control measures were studied and examined. Industrialisation of the inspection system will significantly reduce the company business risk and improve bond quality of bimetal strips.Cold roll bonded (CRB) Al/Al-Sn/Al/steel and sintered CuSnNi/steel bimetal strips are used in the automotive industry for the manufacture of engine bearings, bushes and thrust washers. Any defects such as delamination or porosity that occur in bimetal strips during manufacturing can cause problems at downstream production steps and if they remain undetected, could result in components failing in the field, which is a significant business risk.;One way to reduce this business risk is to install a final inspection system on a continuous production line as the strip passes a fixed inspection point. In process control this could alert the operators to reject defective material and correct process parameters when the defect occurs. As this system requires 100% volumetric inspection, installing it has its challenges due to the harsh manufacturing environment in which the strip moves at up to 20 m/min in the processing lines at room temperature.;A literature review and feasibility study on different non-destructive testing (NDT) techniques to inspect bond quality of CRBed Al/Al-Sn/Al/steel bimetal strips was conducted to assess technologies that could be developed for serial inspection. Guided waves generated using Electromagnetic Acoustic Transducers (EMATs) was identified as best suited for this application. Since this technology was not available off-the-shelf, significant research and experimental work was carried out to develop an automated prototype system.;The system was successfully installed at a strip processing line and demonstrated the online bond inspection capability for Al/Al-Sn/Al/steel and CuSnNi/steel bimetal strips, which is the main achievement of this EngD project. For CuSnNi/steel strips, causes of defects and preventative control measures were studied and examined. Industrialisation of the inspection system will significantly reduce the company business risk and improve bond quality of bimetal strips

Characterization of damage evolution on metallic components using ultrasonic non-destructive methods

When fatigue is considered, it is expected that structures and machinery eventually fail. Still, when this damage is unexpected, besides of the negative economic impact that it produces, life of people could be potentially at risk. Thus, nowadays it is imperative that the infrastructure managers, ought to program regular inspection and maintenance for their assets; in addition, designers and materials manufacturers, can access to appropriate diagnostic tools in order to build superior and more reliable materials. In this regard, and for a number of applications, non-destructive evaluation techniques have proven to be an efficient and helpful alternative to traditional destructive assays of materials. Particularly, for the design area of materials, in recent times researchers have exploited the Acoustic Emission (AE) phenomenon as an additional assessing tool with which characterize the mechanical properties of specimens. Nevertheless, several challenges arise when treat said phenomenon, since its intensity, duration and arrival behavior is essentially stochastic for traditional signal processing means, leading to inaccuracies for the outcome assessment. In this dissertation, efforts are focused on assisting in the characterization of the mechanical properties of advanced high strength steels during under uniaxial tensile tests. Particularly of interest, is being able to detect the nucleation and growth of a crack throughout said test. Therefore, the resulting AE waves generated by the specimen during the test are assessed with the aim of characterize their evolution. For this, on the introduction, a brief review about non-destructive methods emphasizing the AE phenomenon is introduced. Next is presented, an exhaustive analysis with regard to the challenge and deficiencies of detecting and segmenting each AE event over a continuous data-stream with the traditional threshold detection method, and additionally, with current state of the art methods. Following, a novel AE event detection method is proposed, with the aim of overcome the aforementioned limitations. Evidence showed that the proposed method (which is based on the short-time features of the waveform of the AE signal), excels the detection capabilities of current state of the art methods, when onset and endtime precision, as well as when quality of detection and computational speed are also considered. Finally, a methodology aimed to analyze the frequency spectrum evolution of the AE phenomenon during the tensile test, is proposed. Results indicate that it is feasible to correlate nucleation and growth of a crack with the frequency content evolution of AE events.Cuando se considera la fatiga de los materiales, se espera que eventualmente las estructuras y las maquinarias fallen. Sin embargo, cuando este daño es inesperado, además del impacto económico que este produce, la vida de las personas podría estar potencialmente en riesgo. Por lo que hoy en día, es imperativo que los administradores de las infraestructuras deban programar evaluaciones y mantenimientos de manera regular para sus activos. De igual manera, los diseñadores y fabricantes de materiales deberían de poseer herramientas de diagnóstico apropiadas con el propósito de obtener mejores y más confiables materiales. En este sentido, y para un amplio número de aplicaciones, las técnicas de evaluación no destructivas han demostrado ser una útil y eficiente alternativa a los ensayos destructivos tradicionales de materiales. De manera particular, en el área de diseño de materiales, recientemente los investigadores han aprovechado el fenómeno de Emisión Acústica (EA) como una herramienta complementaria de evaluación, con la cual poder caracterizar las propiedades mecánicas de los especímenes. No obstante, una multitud de desafíos emergen al tratar dicho fenómeno, ya que el comportamiento de su intensidad, duración y aparición es esencialmente estocástico desde el punto de vista del procesado de señales tradicional, conllevando a resultados imprecisos de las evaluaciones. Esta disertación se enfoca en colaborar en la caracterización de las propiedades mecánicas de Aceros Avanzados de Alta Resistencia (AAAR), para ensayos de tracción de tensión uniaxiales, con énfasis particular en la detección de fatiga, esto es la nucleación y generación de grietas en dichos componentes metálicos. Para ello, las ondas mecánicas de EA que estos especímenes generan durante los ensayos, son estudiadas con el objetivo de caracterizar su evolución. En la introducción de este documento, se presenta una breve revisión acerca de los métodos existentes no destructivos con énfasis particular al fenómeno de EA. A continuación, se muestra un análisis exhaustivo respecto a los desafíos para la detección de eventos de EA y las y deficiencias del método tradicional de detección; de manera adicional se evalúa el desempeño de los métodos actuales de detección de EA pertenecientes al estado del arte. Después, con el objetivo de superar las limitaciones presentadas por el método tradicional, se propone un nuevo método de detección de actividad de EA; la evidencia demuestra que el método propuesto (basado en el análisis en tiempo corto de la forma de onda), supera las capacidades de detección de los métodos pertenecientes al estado del arte, cuando se evalúa la precisión de la detección de la llegada y conclusión de las ondas de EA; además de, cuando también se consideran la calidad de detección de eventos y la velocidad de cálculo. Finalmente, se propone una metodología con el propósito de evaluar la evolución de la energía del espectro frecuencial del fenómeno de EA durante un ensayo de tracción; los resultados demuestran que es posible correlacionar el contenido de dicha evolución frecuencial con respecto a la nucleación y crecimiento de grietas en AAAR's.Postprint (published version

Scanning evanescent wave lithography for sub-22nm generations

Current assumptions for the limits of immersion optical lithography include NA values at 1.35, largely based on the lack of high-index materials. In this research we have been working with ultra-high NA evanescent wave lithography (EWL) where the NA of the projection system is allowed to exceed the corresponding acceptance angle of one or more materials of the system. This approach is made possible by frustrating the total internal reflection (TIR) evanescent field into propagation. With photoresist as the frustrating media, the allowable gap for adequate exposure latitude is in the sub-100 nm range. Through static imaging, we have demonstrated the ability to resolve 26 nm half-pitch features at 193 nm and 1.85 NA using existing materials. Such imaging could lead to the attainment of 13 nm half-pitch through double patterning. In addition, a scanning EWL imaging system was designed, prototyped with a two-stage gap control imaging head including a DC noise canceling carrying air-bearing, and a AC noise canceling piezoelectric transducer with real-time closed-loop feedback from gap detection. Various design aspects of the system including gap detection, feedback actuation, prism design and fabrication, software integration, and scanning scheme have been carefully considered to ensure sub-100 nm scanning. Experiments performed showed successful gap gauging at sub-100 nm scanning height. Scanning EWL results using a two-beam interference imaging approach achieved pattern resolution comparable to static EWL imaging results. With this scanning EWL approach and the imaging head developed, optical lithography becomes extendable to sub-22 nm generations

The Detection of Stress Corrosion Cracking in Natural Gas Pipelines Using Electromagnetic Acoustic Transducers

This thesis describes the refinement of a non-destructive, in-line inspection system sensor for the detection of stress corrosion cracks (SCCs) in natural gas pipelines. The sensors are prototype electromagnetic acoustic transducers (EMATs) for noncontact ultrasonic inspection. The focus areas discussed involve the statistically validated performance improvements achieved through the addition of 12 more features, the addition of Principal Component Analysis plus Linear Discriminant Analysis (PCA+LDA) to the classification algorithm, and most significantly the creating of a training set. The training set allowed PCA+LDA to be included in the classification algorithm, as well as allowing one set of no-flaw signature features, one PCA projection matrix, and one LDA projection matrix to be used on multiple pipes and on multiple scanned paths from a pipe. A discrete wavelet decomposition is used to separate the frequency content of each EMAT sample (signature) into five distinct bands. From these decomposed signatures, features are extracted for classification. The classification begins with the projection of the features using the PCA projection matrix derived from the training set, immediately followed by the projection of the PCA projected features using the LDA projection matrix that was also derived from the training set. Finally, the PCA+LDA projected features are classified based on their Mahalanobis distances from the PCA+LDA projected no-flaw training set features. Using the improved feature set and this classification procedure, SCC identification improved 14% and there was an 80% reduction in the number of false positives. In addition, there was a 30% improvement in the detection of the most critical SCCs. SCCs whose average through wall depths were between 35% and 54%

Non-destructive quality control of carbon anodes using modal analysis, acousto-ultrasonic and latent variable methods

La performance des cuves d’électrolyse utilisées dans la production d’aluminium primaire par le procédé Hall-Héroult est fortement influencée par la qualité des anodes de carbone. Celles-ci sont de plus en plus variables en raison de la qualité décroissante des matières premières (coke et braie) et des changements de fournisseurs qui deviennent de plus en plus fréquents afin de réduire le coût d’achat et de rencontrer les spécifications des usines. En effet, les défauts des anodes, tels les fissures, les pores et les hétérogénéités, causés par cette variabilité, doivent être détectés le plus tôt possible afin d’éviter d’utiliser des anodes défectueuses dans les cuves et/ou d’apporter des ajustements au niveau du procédé de fabrication des anodes. Cependant, les fabricants d’anodes ne sont pas préparés pour réagir à cette situation afin de maintenir une qualité d'anode stable. Par conséquent, il devient prioritaire de développer des techniques permettant d’inspecter le volume complet de chaque anode individuelle afin d’améliorer le contrôle de la qualité des anodes et de compenser la variabilité provenant des matières premières. Un système d’inspection basé sur les techniques d’analyse modale et d’acousto-ultrasonique est proposé pour contrôler la qualité des anodes de manière rapide et non destructive. Les données massives (modes de vibration et signaux acoustiques) ont été analysées à l'aide de méthodes statistiques à variables latentes, telles que l'Analyse en Composantes Principales (ACP) et la Projection sur les Structures Latentes (PSL), afin de regrouper les anodes testées en fonction de leurs signatures vibratoires et acousto-ultrasoniques. Le système d'inspection a été premièrement investigué sur des tranches d'anodes industrielles et ensuite testé sur plusieurs anodes pleine grandeur produites sous différentes conditions à l’usine de Alcoa Deschambault au Québec (ADQ). La méthode proposée a permis de distinguer les anodes saines de celles contenant des défauts ainsi que d’identifier le type et la sévérité des défauts, et de les localiser. La méthode acousto-ultrasonique a été validée qualitativement par la tomographie à rayon-X, pour les analyses des tranches d’anodes. Pour les tests réalisés sur les blocs d’anode, la validation a été réalisée au moyen de photos recueillies après avoir coupé certaines anodes parmi celles testées.The performance of the Hall-Héroult electrolysis reduction process used for the industrial aluminium smelting is strongly influenced by the quality of carbon anodes, particularly by the presence of defects in their internal structure, such as cracks, pores and heterogeneities. This is partly due to the decreasing quality and increasing variability of the raw materials available on the market as well as the frequent suppliers changes made in order to meet the smelter’s specifications and to reduce purchasing costs. However, the anode producers are not prepared to cope with these variations and in order to maintain consistent anode quality. Consequently, it becomes a priority to develop alternative methods for inspecting each anode block to improve quality control and maintain consistent anode quality in spite of the variability of incoming raw materials.A rapid and non-destructive inspection system for anode quality control is proposed based on modal analysis and acousto-ultrasonic techniques. The large set of vibration and acousto-ultrasonic data collected from baked anode materials was analyzed using multivariate latent variable methods, such as Principal Component Analysis (PCA) and Partial Least Squares (PLS), in order to cluster the tested anodes based on vibration and their acousto-ultrasonic signatures. The inspection system was investigated first using slices collected from industrial anodes and then on several full size anodes produced under different conditions at the Alcoa Deschambault in Québec (ADQ). It is shown that the proposed method allows discriminating defect-free anodes from those containing various types of defects. In addition, the acousto-ultrasonic features obtained in different frequency ranges were found to be sensitive to the defects severities and were able to locate them in anode blocks. The acousto-ultrasonic method was validated qualitatively using X-ray computed tomography, when studying the anode slices. The results obtained on the full size anode blocks were validated by means of images collected after cutting some tested anodes