Setting Discrete Yield-stress Sensors for Recording Early Component Loading Using Eddy-current Array Technology and Induction Thermography

Mroz, Gregor; Reimche, W.; Frackowiak, Wojciech; Bruchwald, Oliver; Maier, Hans Jürgen

doi:10.1016/j.protcy.2014.09.008

Cited by 7 publications

(2 citation statements)

References 3 publications

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“…While the theoretical model works for a multitude of comparatively controlled environments like production plants, it would need to be extended to include further effects (temperature, loading rate) for a broader range of conditions e. g. found in vehicular applications. Further sensor data (temperature, acceleration etc), possibly transmitted from additional networked sensor-integrated machine elements, as well as the supplementary utilisation of the Villari effect (inverse magnetostrictive effect, change of magnetic susceptibility with mechanical stress) [22], which can be evaluated from the established measurement setup [23], can complement interpretation.…”

Section: Discussionmentioning

confidence: 99%

An approach to interpreting metastable austenitic material sensors for fatigue analysis

Heinrich,

Gansel,

Schäfer

et al. 2024

Smart Mater. Struct.

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The transformation of metastable austenite to martensite under mechanical loading can be harnessed to create a material sensor which records a measure of the load history without the need for electrical energy and can be read out at arbitrary intervals via eddy current probing, thus leading to an ultra-low-power sensing solution.This paper presents possibilities of processing this load amplitude-dependent evolution of martensite content loading for component fatigue analysis. The general method is based on using a theoretical material model typically used in FEM analyses which includes hardening plasticity and phase transformation to precompute tables of stress amplitude or cumulative damage corresponding to different sensor readings which can be stored on a low power processing system onboard the component for energy-efficient lookup. At nominal single amplitude loading, the sensor can be used as a load cycle counter for known loads or as an overload detection device upon divergent martensite content rise. Interpretation of block program loading is less practical due to resolution issues. Under random loading, sequence effects get averaged out; interpretation is easiest with narrow load spectra, but information can be gained from very wide spectra as well. Multiple sensors at different locations can aid interpretation. Uncertainty due to necessary assumptions and untreated influences of temperature and loading rate is discussed.

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Section: Discussionmentioning

confidence: 99%

An approach to interpreting metastable austenitic material sensors for fatigue analysis

Heinrich,

Gansel,

Schäfer

et al. 2024

Smart Mater. Struct.

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“…[ 134 ] This sensor arrangement needs a free shaft surface, which is not always available, so that in SHC more integrated solutions are the aim of further research work. Persson & Persson [ 141 ] evaluated also the eddy current displacement sensor, which offers a peak hold function without energy consumption, [ 144 ] which might be a useful feature in long term condition monitoring.…”

Section: Sensor‐integrating Machine Elementsmentioning

confidence: 99%

A Review on Sensor‐Integrating Machine Elements

Kirchner,

Wallmersperger,

Gwosch

et al. 2024

Advanced Sensor Research

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This contribution summarizes the current state of research regarding so‐called sensor‐integrating machine elements as an enabler of digitalization in mechanical engineering and——if available—their application in industry. The focus is on the methodical aspects of the development of these machine elements in general as well as specific sensor‐integrating machine elements that are either already in use or currently under development. Developmental aspects include the robust design of initially evaluated concepts for sensor‐integrating machine elements as well as their modularization. Smart materials with sensory functions are included in the analysis as well as the differentiation with regard to add‐on sensors. The aim of the authors interlinked by a special research program funded by the German Research Foundation (DFG) is to facilitate the exchange with other researchers with the help of the comprehensive overview given in this contribution. The contribution concludes with a brief discussion of open challenges, such as the energy supply and data transfer in rotating systems and also data security.

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Qualification of Austenitic Stainless Steels for the Development of Load-Sensitive Material Sensors

Gansel,

Quanz,

Lohrengel

et al. 2024

J. of Materi Eng and Perform

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To detect mechanical overloads on the component directly in operation, a metastable material can be used as a load-sensitive sensor when combined with an eddy current testing system. In order to find a suitable metastable sensor material that exhibits microstructural changes at an early stage before fatigue failure, quasi-static tensile tests and cyclic rotating bending tests were carried out with the austenitic stainless steels 1.4301 (2 batches), 1.4305, 1.4541 and 1.4550. For the detection of microstructural changes, electromagnetic testing was used in-situ in the tensile test and ex-situ between the rotating bending test after a pre-defined number of cycles. The investigated materials 1.4301 batch2 and 1.4550 showed the largest signal changes and the lowest austenite stability both in the tensile test and under cyclic bending load. Due to the better mechanical properties, 1.4301 batch2 should be preferred. The order of the austenitic stainless steels tested was similar in terms of transformation behavior in both tests. Thus, the tensile test combined with in-situ electromagnetic testing appears to have potential as a suitable benchmark test for austenite stability. With regard to the cyclic bending stress, an overload of the specimens could be detected for the materials 1.4301 batch2, 1.4305, 1.4541 and for the 1.4550 on the basis of a significant amplitude change. At low bending stresses, uncritical for structural integrity, no increase in amplitude was measured. The results have shown that an early detection of overloads is possible with several materials, however, the potential for detecting overloads varies between materials and also between individual batches. In addition, it has been observed that as the bending stress increases, the gradient of the change in amplitude over the number of cycles increases as well. Thus, with a known number of cycles, it could be possible to classify the previous load spectrum based on the difference in amplitude between two measurements.

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Setting Discrete Yield-stress Sensors for Recording Early Component Loading Using Eddy-current Array Technology and Induction Thermography

Cited by 7 publications

References 3 publications

An approach to interpreting metastable austenitic material sensors for fatigue analysis

An approach to interpreting metastable austenitic material sensors for fatigue analysis

A Review on Sensor‐Integrating Machine Elements

Qualification of Austenitic Stainless Steels for the Development of Load-Sensitive Material Sensors

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