Acoustic Characterization of Materials

Prof. Francesco Costanzo –Continuum Mech.Assist. Prof. Regi. Hamilton –Shape Mem Alloys

Dr. Matthew Kropf –BioDiesel

Prof. Clifford Lissenden –Struct. Health Monit.

Adj. Prof. Chiaki Miyasaka –Thin Film Adh.Prof. Joseph Rose –Guided Waves in Pipes

Prof. Bernie Tittmann -Group Leader

Center of Acoustics & Vibration 2011 CAV

OUTLINE of Presentations

• [1] “Ultrasonic Applications in the Energy Industry” by Dr. Matthew Kropf

• [2] “Ultrasonics” Prof. Joseph Rose

Ultrasonic Applications in the Energy Industry

Presented by: Matt KropfEngineering Nano-Characterization Laboratory: Dr.

Bernhard TittmannDavid Parks, Cliff Searfass, Brian Reinhardt, Xiaoning

Xi, Ryan Johnson, Shawn Getty

Outline

• Nuclear Power Industry– Sensor Developments– Techniques and Applications

• Utility Grade Electricity Production– Turbine Blade sensors

• Biofuels– Biodiesel– Cellulosic Ethanol

ULTRASONICS IN THE NUCLEAR POWER INDUSTRY

Ultrasonics in harsh environments

Problem Statement

4

• Aging Nuclear Reactor Facilities Life Extensions– Economic Viability– Structural Integrity

• Generation IV Condition Based Maintenance Paradigm

• Need for radiation damage characterization

Life Beyond 60 Workshop Summary Report. Bethesda, Maryland : Energies Incorporated, 2008.

Ultrasound for Nuclear Power

• Environmental Considerations– Temperatures– Pressures– Environment– Radiation

• Piezoelectric Sensitivities– Curie Temperature– Lattice disruption– Thermal Expansion

General Requirements

• High temperature capability– Hard ferroelectrics

• Bismuth Titanate• Lithium Niobate

– Relative Permittivity < 30 , ρ 106 – 108 Ωcm– Polar Single Crystals

• AlN• ZnO• GaPO4

– Relative Permittivity < 30 , ρ 103 – 109 Ωcm– Low relative permittivity and low resistivity can be detrimental

• Radiation Resistant• Easy disposal

Technical Implementation

radiation hardened cable

Reactor Results – 3 months

Nonlinear WavePropagation

9

I. Linear Wave Dynamicsi. Hooke’s Lawii. Atoms move togetheriii. Constant Frequency

II. Nonlinear Wave Dynamicsi. Higher order terms in

strain energy densityii. Nonlinear Constitutive

relationship

Cantrell, John. H. Fundamentals and Application of Nonlinear Ultrasonic Nondestructive Evaluation. [book auth.] Tribikram Kundu. Ultrasonic Nondestructive Evaluation: Engineering and Biological Material Characterization. s.l. : CRC Press, 2004.

Contribution from damage

10

I. Damagei. Dislocations, Interstitials,

Vacanciesii. Stacking Faults, Precipitates

II. Contributioni. Nonlinear Strain

Component

Cantrell, John. H. Fundamentals and Application of Nonlinear Ultrasonic Nondestructive Evaluation. [book auth.] Tribikram Kundu. Ultrasonic Nondestructive Evaluation: Engineering and Biological Material Characterization. s.l. : CRC Press, 2004.

Concept- Ultrasonic SAW for Fuel Pellet Inspection

Fuel Fuel FuelGraphite Graphite

AISI 304 or Z7CN18.09 Cladding

Wedge WedgeAlN AlN

Experimental Design

1”

Aluminum Nitride (AlN15)

Aluminum

Wedge714-ph Stainless Steel

In-SituPeriodic

ULTRASONIC APPLICATIONS TO ELECTRIC POWER GENERATION

Ultrasonic sensors for turbine blade monitoring

Ultrasonic Monitoring of Turbine Blades

• Environmental Considerations– Temperature– Pressure– Environment– Mechanics

• Geometry• Motion

• Piezoelectric Limitations– Curie Temperature– Conformal application

Ultrasonic Monitoring of Turbine Blades

• Problem Statement: Developing ultrasonic transducers that can operate (reliably) at high temperatures (>1000 oC).

• Difficulties:– Ultrasonic coupling at high temperatures– Maintaining contact in hazardous and/or remote environments– High Curie temperature ferroelectric or high melting point

piezoelectric required• Bi4Ti3O12, Bi3TiNbO9 , LiNbO3, La2Ti2O7, Sr2Nb2O7 La3Ga5SiO14, GaPO4, AlN

– Single crystals can be difficult to work with.• Thermal expansion mismatch over extended temperature range.• Fragile

Piezoelectric Materials for Harsh Environments

• Sol-gel spray-on advantages:– Potential to eliminate the need of

couplants at high temperature.– Good matching of thermal

expansion between ceramics and metal (more details later).

– Can make thick film materials.– Means of maintaining contact are

eliminated.– Potential for complex geometries.– Transducers have good piezoelectric

response.

Technical Implementation

• Temperature Testing

ULTRASONICS IN THE BIOFUELS INDUSTRY

Ultrasonic sensors and actuators for the research and processing of biofuels.

Concept

• Biodiesel Reaction

• Immiscible units of alcohol and oil are mixed and heated drive the reaction

Vegetable Oil plus Alcohol Catalyst Equals(Triglyceride) (methanol and sodium hydroxide)

Glycerol

Biodiesel (Methyl Ester)

State of the Art

• On the industrial scale:– Long heated and stirred batches

• Higher Temperatures– Higher Conversion Rate

• More Intense Mixing– Higher Conversion Rate

Technological Innovation• Mixing is achieved through ultrasonic emulsification,

resulting in highly uniform mixtures• The resulting emulsion is rapidly heated by selective

application of microwave frequencies focused on methanol

0

2

ρε

pCtT E′′∝

∂∂

Mixing by Micro-Jetting

1) Immiscible Solution

Alcohol

Oil

3) Emulsion Complete

2) Ultrasonic Cavitation

Ultrasonic Emulsification

Conventional

44kHz Ultrasonic

Benefits at 1 Mgal/Year

0

50,000

100,000

150,000

200,000

250,000

0 5 10 15 20 25

$ Sa

ving

s / y

ear

Cents / kW-h

Electricity Savings

0

50,000

100,000

150,000

200,000

250,000

0 1 2 3 4 5 6 7

25%

Sod

ium

Met

hoxi

de

(kg)

% FFA

DIAGNOSTIC ULTRASOUND IN BIO-FUEL RESEARCH

Low intensity ultrasonic measurements

Pure Tone Harmonics

Non-Linear Ultrasound for Fuel Quality

Integrated Liquid Level/Quality Measurement

0

0.01

0.02

0.03

0.04

0.05

0.06

1 2 3 4 5

Liqu

id le

vel (

m)

Configuration number

OilWater

A E Resources Company Confidential

Diagram of the Scanning Acoustic Microscopy (SAM)

V: the amplitude of output microscope signalZ: the distance between the object and lens focal plane

V vs z curve

Working principle

Curve fitting result:Surface wave velocity: 1628 m/s

Input sample parameter:Thickness: 8 µmDensity: 1.04 g/cm^3

Matching experimental and simulation results

Fresh onion skin sample on (100) silicon wafer

Average thickness: 8µm

Temperature: 22 ℃

Acoustic lens model: AL4M350 (f= 400 MHz)

onion density input number: 1.4 g/cm^3

Matching results for V(z) curves in five positions on the sample:

1625 m/s, 1630 m/s, 1628 m/s, 1630m/s, 1615m/s

Average velocity: 1626 m/s (1610 m/s for onion cell in paper)

Preliminary results

Conclusion

• Nuclear Power:– Robust transduction– Advanced measurements

• Utility Electric– Robust and conformal transduction– Innovative processing technique

• Bio-fuels production– Innovative processing approach– Novel Sensor strategies– Advanced measurements for fundamental research

Ultrasonic Guided Waves for NDT and SHM

Joseph L. RosePaul Morrow Professor Penn State University

Center for Acoustics and Vibration

May 9-10,2011

Reasons to Consider GW (understanding and computational power developments)

• Paradigm Shift from Bulk Wave Ultrasonics to Guided Wave– Cost– Less inspection time and greater coverage – Solving new problems with no prior solution potential

• Paradigm Shift from NDE to SHM– Reliability, continuous screening, early warning– Baked in potential for prefab sensor installation– Cost and safety benefits

Natural Waveguides

• Plates (aircraft skin)• Rods (cylindrical, square, rail, etc.)• Hollow cylinder (pipes, tubing)• Multi-layer structures• An interface

Principal Engineering Benefits of Guided Waves

Inspection over long distances from a single probe position.

Ability to inspect hidden structures and structures under water, coatings, soil, insulations, and concrete.

The Hybrid Analytical FEM Approach

Phased Arrray Technologies( medical, bulk, guided)

Guided wave active focusing in pipeFE simulation results

Transducer array located at pipe endArray can be segmented into 4 or 8 channels.Time delays are applied.

1 2 3 4 5 Focus beam forming

Focused guided wave beam

o

o

Rail coverage as a function of mode selection

Tomography

Affected path 1 Affected path 2

Ultrasonic transducers placed in an array around an area of interest

Damage Location suggested by the intersection

• Reconstruction Algorithm for Probabilistic Inspection of Damage (RAPID)

P(x,y) 1 1 2 21

1( ( , , , , , ) )1 1

N

k k k k kk

A R x y x y x y ββ β=

−= +

− −∑

1

2

(x,y)Signal difference coefficient (SDC)

SDC = 1-ρ , R – ratio of distance of the path taken and line of sight

ρ – correlation between signals in the reference and damaged states

CT Testing of Ballistic Damage to Fabricated Armor Panel

Target

1st shot

2nd shot

The panel was impacted twice with a .177 caliber lead pellet at a velocity of 1000 ft/sec. The impacts created a visible damage region of approximately a 1 in diameter circle.

MsS and EMAT Devices

Long Range GW pipe InspectionBuried SHM SystemsUtomo Tomography

Bondometer, etc.

Ultrasonic Guided Wave Beam Steering in Plates Using Phased Arrays

Notes: Guided wave beam can be steered into different directions by applying phase delays to the elements of an array, circular array example.

Tubing Bridges

Ultrasonic VibrationIce Detection and De-icing

Gas Entrapment

Thank You Very Much