Comparison of numerical models for Acoustic Emission propagation

Abstract Acoustic Emissions (AE) are at the basis of extremely accurate and reliable monitoring systems. Within the SmartBench project, data regarding structural health of components are gathered in a database in order to make safety integrated, operative and smart. An accurate modelling of wave propagation is a necessary requirement for a proper design of sensor networks as well as for data interpretation. Numerical simulations of the transient behavior of structural systems are well-established in this field but, on the minus side, they are very expensive in terms of computational time and resources. This paper reports different instances of AE propagation through metallic media. Bulk waves and guided waves are both investigated by means of 2D and 3D models and resorting to different software. Obtained results are cross-checked and computational times are compared as well. As a last point, High Performance Computing is applied to the case of waves simulation in order to get a significant reduction of the required computational time

A digital shadow cloud-based application to enhance quality control in manufacturing

In Industry 4.0 era, rapid changes to the global landscape of manufacturing are transforming industrial plants in increasingly more complex digital systems. One of the most impactful innovations generated in this context is the "Digital Twin", a digital copy of a physical asset, which is used to perform simulations, health predictions and life cycle management through the use of a synchronized data flow in the manufacturing plant. In this paper, an innovative approach is proposed in order to contribute to the current collection of applications of Digital Twin in manufacturing: a Digital Shadow cloud-based application to enhance quality control in the manufacturing process. In particular, the proposal comprises a Digital Shadow updated on high performance computing cloud infrastructure in order to recompute the performance prediction adopting a variation of the computer-aided engineering model shaped like the actual manufactured part. Thus, this methodology could make possible the qualification of even not compliant parts, and so shift the focus from the compliance to tolerance requirements to the compliance to usage requirements. The process is demonstrated adopting two examples: the structural assessment of the geometry of a shaft and the one of a simplified turbine blade. Moreover, the paper presents a discussion about the implications of the use of such a technology in the manufacturing context in terms of real-time implementation in a manufacturing line and lifecycle management. Copyright (C) 2020 The Authors

The DEMO magnet system – Status and future challenges

We present the pre-concept design of the European DEMO Magnet System, which has successfully passed the DEMO plant-level gate review in 2020. The main design input parameters originate from the so-called DEMO 2018 baseline, which was produced using the PROCESS systems code. It defines a major and minor radius of 9.1 m and 2.9 m, respectively, an on-axis magnetic field of 5.3 T resulting in a peak field on the toroidal field (TF) conductor of 12.0 T. Four variants, all based on low-temperature superconductors (LTS), have been designed for the 16 TF coils. Two of these concepts were selected to be further pursued during the Concept Design Phase (CDP): the first having many similarities to the ITER TF coil concept and the second being the most innovative one, based on react-and-wind (RW) Nb3Sn technology and winding the coils in layers. Two variants for the five Central Solenoid (CS) modules have been investigated: an LTS-only concept resembling to the ITER CS and a hybrid configuration, in which the innermost layers are made of high-temperature superconductors (HTS), which allows either to increase the magnetic flux or to reduce the outer radius of the CS coil. Issues related to fatigue lifetime which emerged in mechanical analyses will be addressed further in the CDP. Both variants proposed for the six poloidal field coils present a lower level of risk for future development. All magnet and conductor design studies included thermal-hydraulic and mechanical analyses, and were accompanied by experimental tests on both LTS and HTS prototype samples (i.e. DC and AC measurements, stability tests, quench evolution etc.). In addition, magnet structures and auxiliary systems, e.g. cryogenics and feeders, were designed at pre-concept level. Important lessons learnt during this first phase of the project were fed into the planning of the CDP. Key aspects to be addressed concern the demonstration and validation of critical technologies (e.g. industrial manufacturing of RW Nb3Sn and HTS long conductors, insulation of penetrations and joints), as well as the detailed design of the overall Magnet System and mechanical structures

Design of a lightweight chassis for the land speed record vehicle Buckeye Bullet 2

The design of a novel chassis solution for a land speed record streamliner, the Buckeye Bullet 2, which represents an evolution of the vehicle that recently set various records in the electric vehicle classes is addressed in this paper. Various architectures for a lightweight solution are investigated considered. The reference chassis design of the Buckeye Bullet consists of a steel space frame structure, for which alternative candidate solutions are investigated. These include several combinations of aluminium honeycomb sandwich panels and carbon fibre composite skins and a composite monocoque structure. A high-speed streamliner requires a chassis that is stiff in both torsion and bending, especially in transversal direction, in order to avoid undesired vibrations that can compromise vehicle handling. Thus, the various solutions are compared on the basis of mass, stiffness and eigenfrequencies. Finally, this paper investigates chassis strength with respect to torsional and bending loads that produce critical stresses for the reference structure and for operative loads

Fatigue cracks nucleation on steel, acoustic emission and fractal analysis

In this paper, a new acoustic emission (AE) diagnostic technique, for the study of fatigue cracks nucleation and propagation on steel, was investigated. Using the fractal analysis, and the box-counting method (BCM) in particular, it is possible to characterize the spatial distribution of the prime AE sources through the fractal dimension (D) that evolve with the number of fatigue cycles (N) of the specimen. D-N curves were found useful to identify the condition of incipient collapse due to the nucleation and propagation of fatigue cracks on steel. It is possible to use the fractal dimension as a damage parameter. In all tested specimens, the crisis occurs within the same range of values of fractal dimension. The results suggest that it is possible to anticipate the detection of crack beginning relating to the other theoretical or experimental techniques. (c) 2006 Elsevier Ltd. All rights reserved