Design and development of micro-electromechanical acoustic emission sensors

Non-Destructive Testing (NDT) is a vital technique in modern engi- neering, enabling the monitoring of the structural health of a com- ponent and therefore enabling the prediction of component failure. Once the structural health of a component is known, timely main- tenance can be carried out to prevent component failure which may have resulted in costly downtime or injury. One NDT technique which has been of increasing interest over recent years is Acoustic Emission (AE) monitoring. AE monitoring technology has been successfully combined with preventative maintenance, saving millions of pounds worldwide.EThOS - Electronic Theses Online ServiceGBUnited Kingdo

Characterization Of Wave Propagation Through Composite Laminates

Structural Health Monitoring (SHM) seeks to develop systems for data collection, verification, and analysis to detect the potential for critical damage to occur in engineering structures. Composite panels are engineering structures that are susceptible to damages such as delamination and fiber breakage which greatly reduce the safety and performance of the structure. For composite materials that are widely used in aviation, early detection of such damage is important to prevent failure while the component is in flight. A common SHM method for damage assessment of composites is the Lamb wave propagation technique, whereby waves may be introduced into the composite panel via piezoelectric transducers. The propagating waves are measured after traveling through the region of interest to detect damage present in that region. Scanning laser vibrometry is a method often used to detect wave propagation patterns. The method is beneficial in that it is noncontact, nondestructive, and can be applied to virtually all geometries. Wave propagation patterns in composite panels are different from those seen in isotropic plates due to their anisotropy and the viscoelastic nature of the matrix materials. The use of a scanning laser vibrometer (SLV) to characterize wave propagation through a composite panel was explored in the present research. The characteristics of interest were the directionality of the propagating wave\u27s amplitude, velocity, and attenuation. Thin lead-zirconate-titanate (PZT) actuators were bonded to an undamaged carbon/epoxy composite panel and pulsed to extract the wavefields using the SLV. Numerical simulations of the experiments were also performed to verify the results

Guided Lamb Wave Based 2-D Spiral Phased Array for Structural Health Monitoring of Thin Panel Structures

In almost all industries of mechanical, aerospace, and civil engineering fields, structural health monitoring (SHM) technology is essentially required for providing the reliable information of structural integrity of safety-critical structures, which can help reduce the risk of unexpected and sometimes catastrophic failures, and also offer cost-effective inspection and maintenance of the structures. State of the art SHM research on structural damage diagnosis is focused on developing global and real-time technologies to identify the existence, location, extent, and type of damage. In order to detect and monitor the structural damage in plate-like structures, SHM technology based on guided Lamb wave (GLW) interrogation is becoming more attractive due to its potential benefits such as large inspection area coverage in short time, simple inspection mechanism, and sensitivity to small damage. However, the GLW method has a few critical issues such as dispersion nature, mode conversion and separation, and multiple-mode existence. Phased array technique widely used in all aspects of civil, military, science, and medical industry fields may be employed to resolve the drawbacks of the GLW method. The GLW-based phased array approach is able to effectively examine and analyze complicated structural vibration responses in thin plate structures. Because the phased sensor array operates as a spatial filter for the GLW signals, the array signal processing method can enhance a desired signal component at a specific direction while eliminating other signal components from other directions. This dissertation presents the development, the experimental validation, and the damage detection applications of an innovative signal processing algorithm based on two-dimensional (2-D) spiral phased array in conjunction with the GLW interrogation technique. It starts with general backgrounds of SHM and the associated technology including the GLW interrogation method. Then, it is focused on the fundamentals of the GLW-based phased array approach and the development of an innovative signal processing algorithm associated with the 2-D spiral phased sensor array. The SHM approach based on array responses determined by the proposed phased array algorithm implementation is addressed. The experimental validation of the GLW-based 2-D spiral phased array technology and the associated damage detection applications to thin isotropic plate and anisotropic composite plate structures are presented

Signal processing methods for defect detection in multi-wire helical waveguides using ultrasonic guided waves

This thesis was submitted for the degree of Master of Philosophy and awarded by Brunel University LondonNon-Destructive Testing of industrial components carries vital importance, both financially and safety-wise. Among all Non-Destructive techniques, Long Range Ultrasonic Testing utilizing the guided wave phenomena is a young technology proven to be commercially valid. Owing to its well-documented analytical models, Ultrasonic Guided Waves has been successfully applied to cylindrical and plate-like structures. Its applications to complex structures such as multi-wire cables are fairly immature, mainly due to the high complexity of wave propagation. Research performed by the author approaches the long range inspection of overhead transmission line cables using ultrasonic guided waves. Existing studies focusing on guided wave application on power cables are extremely limited in inspection range, which dramatically degrades its chances of commercialization. This thesis consists of three main chapters, all of which approaches different problems associated with the inspection of power cables. In the first chapter, a thorough analysis of wave propagation in ACSR (most widely used power cable) cables is conducted. It is shown that high frequency guided waves, by concentrating the energy on the surface layers, can travel much further in the form of fundamental longitudinal wave mode, than previous studies have shown. Defect detection studies proved the system’s capability of detecting defects which introduce either increase or decrease in cross sectional area of the cable. Results of the chapter indicate the detectability of defects as small as 4.5% of the cross sectional area through a 26.5 meter long cable without any post-processing. In the second chapter, several algorithms are proposed to increase the inspection range and signal quality. Well-documented wavelet-denoising algorithm is optimized for power cables and up to 24% signal-to-noise ratio improvement is achieved. By introducing an attenuation correction framework, a theoretical inspection range of 75 meters is presented. A new framework combining dispersion compensation and attenuation correction is proposed and verified, which shows an inspection range of 130 meters and SNR improvement up to 8 dBs. Last chapter addresses the accurate localization of structural defects. Having proven the optimum excitation and related wave propagation in ACSR cables, a system having a more complex wave propagation characteristics is studied. A new algorithm combining pulse compression using Maximal Length Sequences and dispersion compensation is applied to multi-modal signals obtained from a solid aluminum rod. The algorithm proved to be able to improve signal quality and extract an accurate location for defects. Maximal Length Sequences are compared to chirp signals in terms of SNR improvement and localization, which produced favourable results for MLS in terms of localization and for chirp in terms of SNR improvement

Development of lightweight structural health monitoring systems for aerospace applications

This thesis investigates the development of structural health monitoring systems (SHM) for aerospace applications. The work focuses on each aspect of a SHM system covering novel transducer technologies and damage detection techniques to detect and locate damage in metallic and composite structures. Secondly the potential of energy harvesting and power arranagement methodologies to provide a stable power source is assessed. Finally culminating in the realisation of smart SHM structures. 1. Transducer Technology A thorough experimental study of low profile, low weight novel transducers not normally used for acoustic emission (AE) and acousto-ultrasonics (AU) damage detection was conducted. This included assessment of their performance when exposed to aircraft environments and feasibility of embedding these transducers in composites specimens in order to realise smart structures. 2. Damage Detection An extensive experimental programme into damage detection utilising AE and AU were conducted in both composites and metallic structures. These techniques were used to assess different damage mechanism within these materials. The same transducers were used for novel AE location techniques coupled with AU similarity assessment to successfully detect and locate damage in a variety of structures. 3. Energy Harvesting and Power Management Experimental investigations and numerical simulations were undertaken to assess the power generation levels of piezoelectric and thermoelectric generators for typical vibration and temperature differentials which exist in the aerospace environment. Furthermore a power management system was assessed to demonstrate the ability of the system to take the varying nature of the input power and condition it to a stable power source for a system. 4. Smart Structures The research conducted is brought together into a smart carbon fibre wing showcasing the novel embedded transducers for AE and AU damage detection and location, as well as vibration energy harvesting. A study into impact damage detection using the techniques showed the successful detection and location of damage. Also the feasibility of the embedded transducers for power generation was assessed