7A ods 559 STRUCTURAL ~ HEALTH MONITORING 2003 From Diagnostics & Prognostics To Structural Health Management Edited by Fu-Kuo Chang Department of Aeronautics and Astronautics Stanford University, Stanford, CA 94305 Proceedings of the 4th International Workshop on Structural Health Monitoring, Stanford University, Stanford, CA. ‘September 15-17, 2003, ‘Sponsors: Air Force Office of Scientific Research ‘Army Research Office National Science Foundation “ooo Q “3 DES¢tech Publications, Inc. WY 29°07 554 509 3Structural Health Monitoring 2003 DBSech Publisions, nc. 1148 Binabeth Avene #2 Lancaster Pennsyvania 17601 USA. CCopyeigh © 2008 by DEStech Publications, Inc. Allighs reserved No ptf this publication may be reproduce stored in a reieval system, or transmitted, in any form or by any means, clearonic, mechanical, photocopying recording, or tberwse, ‘without the price ween permission ofthe publisher Printed inthe United States of America wos7 6S 4321 Main entry under: Proceedings ofthe th tntematonal Workshop on Structural Health Monitoring 2003, From Diagnotice & Progrosics wo Suuctua Health Management |A DEStech Publications book Bibliography p Includes index 9.1547 ISBN No. 1-932078.20-7Table of Contents xx Application of Fibre Optic Strain Sensors for the Health Monitoring of Adhesively Bonded Composite Ship Joints... « H'C.H.U.,C. DAVIS, | HERSZBERG, A’P MOURITZ, S.C. GALEA and R. §. THOMSON Fiber Optic System for 2-D Strain Measurement in Parachutes... 2... beeeeee 1335 M. ELSHERIF.M, Li, D. ELSHERIF M. HIDAYET, ‘A, RAHMAN and C, LEE Real-Time Fatigue Monitoring Of Deepwater Drilling and Oil Production Risers Using Fiber-Optic Sensors... .. 1343 D.V. BROWER Full Cure Monitoring by Fiber Optic Dual Functionality Sensing System... . 2... eee M, GIORDANO, A. LAUDATI, M. RUSSO, J. NASSER, ‘A. CUTOLO and A. CUSANO ‘Comparative Vacuum Monitoring as an Alternate Means of Compliance ......-++- +--+ G. WHEATLEY, J. KOLLGAARD, J. REGISTER and M. ZAIDI Gear Box Health Monitoring Through Three Phase Motor Current Signature Analysis... 5. + ‘A.B. MOHANTY and C. KAR Identification of Coupling Misalignment in a Rotor-Coupling-Bearing System AS. SEKHAR, A.Laser Scanning Technique for Fatigue Damage Precursor Detection and Monitoring... . . ween eee 1388 B.D. BUCKNER, V MARKOV, J. C. EARTHMAN and J-ANGELES Built-In Detection of Impact Damage in Multi-Layered ‘Thick Composite Structures, ......4.. + vee e eee ees 1391 J. PARK and F-K. CHANG = 1351 cs 1366 = 1374 POSTER Dynamic Properties of Synthesis System via Considering the Effect of Equipment and Structure... . 0... e es ees 1401 J. ZHANG and ¥. LEIA Laser Scanning Technique for Fatigue Damage Precursor Detection and Monitoring B. D. BUCKNER, V. MARKOY, J. C. EARTHMAN and J. ANGELES ABSTRACT I is commonly supposed tht the surface layer of a solid must be considered as a particular state of a erysial [I]. The peculanties of surface layer deformation of ‘mechanically cycled samples have been observed in alge numberof investigations. ‘This includes formation of sres-induced surface defects, suchas microcracks, romps and slipbands. Although such phenomena are yet to be wholly understood, the ‘examination of such surface changes can provide data on the fatigue state of the ‘component, serving as fatigae damage precursors. This information then can be used in remaining fatigue lie prognostics, In this report we describe a laser based technique that, by studying the stress- induced changes ofthe surface, allows detection of fatigue damage growth at an early stage. The basis for ths ‘echnique isto scan a focused laser beam over the component surface and to observe changes in the scattered light asthe beam sweeps across i ‘This scattering signal display clear peaks asthe beam sweeps over microcracks, and, additionally, the microscale surface texture (roughness) affects the both the mean signal level and (ander coherent illuination) the statistical properties of the speckle. ‘The surface microcrack density tends to increase in a characteristic pattem as the fatigue progresses ‘n the component. Surface microroughness evolution can be Somewhat more complex, but It does give some information about the state of the sample. ‘We have investigated fatigue damage precursors on the surfaces of several types ‘of samples under high and low.cyele fatigue conditions. By counting discrete surface defects to derive a scalar frequency, rather than digitally acquiring whole signal ‘waveforms, we minimize memory requirements and data processing time. As a result, the present technique is capable of scanning speeds that are substantially greater than those achieved with image processing methods. Inconel 718 test specimens, sections of the nickel-based superalloy turbine rotor and aluminum specimen were tested using a servo-hyraulie MTS machine at ambient temperature under load control conditions. ‘Barjarin Bcekne and Viadimir Markov, MetoLaser, Inc, 2572 White Rd, vine, CA 92614, James Earhman and Joel Angeles, Department of Cheical Engineering and Materials Science, The Henry Samal Senod of Engineering, Univers of Calfomia, vine, CA 82607-2575. 13831384 SPECIAL APPLICATIONS. The fatigue damage was monitored by scanning a laser beam along the rotor section in situ and during periodic interruptions ofthe cyclic loading, ‘Acetate replicas ofthe gage section surface were also made to examine the surface morphology using SEM, Comparisons of the results demonstrate the capabilites of the present light scanning technique for characterizing faigue damage precursors cn the surface of turbine components. In particular, a rapid rise in the mean defect frequency is shown to correspond to the emergence of surface relief features that follow the grain boundaries intersecting the surface inthe areas of greatest sess, The presence of this surface relief can be attributed to the presence of relatively soft precipitate free zones along the grain boundaries that preferentially deform under fatigue loading conditions leading to the formation of microcracks. Results have been obtained on aluminum samples under low cycle fatigue as well, in which we have observed the defect frequency to be elevated on regions of the surface where strain is expected to be concentrated This technology is being pursued both for laboratory and field use, and MetroLaser is developing it ina portable form forthe latter. We have also investigated approaches to utilize compact beam scanning devices to develop the technology as a basis for in situ structural health monitoring in several areas. It is anticipated that scanning sensors can be developed with a surface footprint in the range of 20 em? and few centimeters in height INTRODUCTION Detecting and monitoring fatigue damage is needed for preemptive failure repir ‘or replacement of critical components in engineering systems. A macroscopic crack however doesnot generally manifest until very lt inthe kifeof the component under high eyele fatigue (HCP) conditions. Therefore, itis of wea importance to develop methods to quickly detect localized deformation and microcracking early in the fatigue life, well in advance of microcrack coalescence and macrescopic cack ‘row, Since surface structural changes and microcracks ean oecur much earie on the sursce, thee precusory effets could be used to monitor the development ofthis fatigue crack formation tat lea o catastrophic fare (2) arly in the fatigue process, dislocations in crstaline solids migrate to give vise to localized deformation, which in tum leads to micro-cack initiation and eventual failure. Crack formation ypealy curs ver lat in fatigue life (within te ast 200) under high eyle fatigue canditons and, therefore, erly determination of fatigue and estimation of remaining lie requires the detection of dislocation structures as UY impinge on te surface ofthe specimen. Optical visualization of precursor dislocation strtures prior t0 crack formation is generally mot possible for engineering components, However, in materials that have moderate to high surface resis! stresses, the initial formation and movement of dislocations can reduce soriace residual stress (3), The relationship between cyclic lading and a decreas in residual stress has been observed and reported by many researchers [49]. For example substan relaxation of residual stresses during fatigue loading was observed using the x-ray diffraction techniques {10}. The elation of residual stresses by 30% mild steel under fatigue loading conditions was also measured using high sensitivity Moire interferometry (11 Similny, a laser light seatering technique was show ©Laser Scanning Technique for Fatigue Damage Precursor Detection and Monitoring 1388 efficiently detect not only microcracks, but also a reduction in surface roughness on wire specimens that were subjected to high cycle fatigue conditions. This change in roughness was atributed to cyclic relaxation of lange residual stresses at the surface that resulted from the wire drawing process. Various techniques have been proposed for the optical measurement of surface roughness and defect detection including laser ultrasonic [12], laser Doppler vibrometry {13}, interferometry (14], and scattered light scanning [2], It follows from the comparative analysis performed during the inital stages of the resent work that although the interferometric and LDV methods have sufficient sensitivity, the techniques based on scattered light detection are more reiable, simpler in operation, and have the owest cost to implement. ‘Additionally, corrosion can hasten component failure in many materials, and corrosion typically manifests itself early on the surface. Inspection and monitoring of component surfaces, particularly around critical areas, can thus give us @ window on several important indicators of developing fatigue damage. ‘This we are developing a new technology based on light-scattering inspection of ‘component surfaces, with particular emphasis on portable and insite implementations, which are enabled by the relative technological simplicity of the method, TECHNIQUE Light scanering isa well developed technique, used for metrology in number of applications {15}. In this application, we desire to detect and monitor randomly positioned features, so we sean focused laser beam over the surface aad measure Signal peaks, which are associated with localized surface features. A pre-focused scanning geometry is used, with the scan ine generated by a rotating polygonal mito ora galvanometer("galvo") seanner, Since the features are randomly positioned with effectively stationary statistics over a distance of atleast millimeters, sean errr is not significant. We have inspected a number of aircraft parts with breadboard systems and a Iaboratory system at UCI and identified scaltering signals correlated to cracks and other fatigue-induced defects in their surfaces. These include both airframe components and turbine components, wth a varity of surface types and textures. ‘The prototype scanaing systems, including our latest portable system, have sequited data by both whole-waveform acquisition of the scattering signal and counting of peaks from hardware-based peak detection, and they appear to be relatively insensitive to envionmental surface contaminants such as particles, thoush high-profile texture with lateral dimensions in te milieter to micron range can be Aisruptve ‘These experiments have demonstrated that stress cracks on surfaces are easily detectable with compact and inexpensive components, particulary with regard to the laser source. The MetroLaser portable system uses 2 70 jum focal spot and a working distance of around 20 em, with a scan rate of up 10600 Hz. An in-situ system can be ‘expected to achieve a better focus than this long-working-stance prototype, with a spot of 50 um or less, implying even better SNR.1386 ‘SPECIAL APPLICATIONS. Figure | shows atypical plot of fatigue precursor suface density, illustrating the 3 phases of surface development that are consistently observed in these experiments, ? pads ' i € , . 3 £0. 4 1 a § zo so 40 eo 60 70 8 oust coe ~ Figure 4, 1250 Hz scan of mean defect fropencis over an Al sample (a hole ine sample appears at around 3 mm ~ note te high defet frequency near one 8Laser Scanning Technique for Fatigue Damage Precursor Detection and Monitoring 1389 ‘These relationships are typical ofthe information we will collect to inform the prognostic models ultimately needed to enable failure time estimation. SUMMARY Fatigue damage on the surface of several samples, including turbine blade/rotor sections and aluminum test specimen were monitored using a scattered light laser scanning system developed for rapid detection, Substantially greater values of the parameter we define as defect frequency were observed in higher stressed regions of the surface by scanning the sample during interruptions of the cyclic loading. Furthermore, the average defect frequency determined during eycling for these higher stresses regions gradually increased with load cycling. Surface replications with acetate fim also made during the interruptions in cyclic loading revealed that the increase in defect ffequency corresponds to the formation of grooves in the regions of highest stress. Residual stress measurements for tested and untested samples indicate thatthe grooves were not associated witha relaxation of residual stresses. Rather, they appear to have resulted from localized slip processes along the grain boundaries. Following testing, the presence ofthese grooves was confirmed by direct SEM of the sample surface ACKNOWLEGEMENT ‘The research reported here is supported by a US ARMY and NASA SBIR contracts # DAAHIO-02-C-0007, and #NAS4-030084, respectively REFERENCES [1] Zangwil A. Phys of Sufaces, Uaivesity Pres, Cambridge, 1988, p 536 [2] Schmid, P. and J Esrdran’ 1995. “Development of + Scanning Laser Croce Destin “Tebnique fox Conasion Fugue Testing of Fine Wie" J Mater Rex. 100), p.372 [5] Farhi, GH 11 Lebrun, and D. Couatin. 1995. “Ect of Shot Pening on Residual Stes and Fatigue Lif of Spring Stel" Fatigue ond Froctre of Eng Mat and Siac, 18(2)211-220, (4) Fiepatic, ME. and L, Edwards. 1998, "Fatigue Crac/Resdual Sess Field Interaction and “Ther Implication for Damage‘Tlerant Design. “J Mat. Eng and Per 12) 190-198, [5] Edvard Land AT. Ondemic. 1998. 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