Table Of ContentHandbook of Technical Diagnostics
Horst Czichos
Editor
Handbook of Technical
Diagnostics
Fundamentals and Application
to Structures and Systems
1 3
Editor
Horst Czichos
Beuth HochschulefürTechnik
Berlin
Germany
ISBN 9783642258497 ISBN 9783642258503 (eBook)
DOI 10.1007/9783642258503
SpringerHeidelbergNewYorkDordrechtLondon
LibraryofCongressControlNumber:2012955407
(cid:2)SpringerVerlagBerlinHeidelberg2013
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Preface
Functionality,quality,reliability,andsafetyareindispensableattributes
of all technologies. This handbook presents concepts, methods, and
techniques to examine symptoms of fault and failure of structures,
systems, and components to monitor functional performance and
structural integrity.
The book is organized in five parts:
• Part I introduces the scope and application of technical diagnostics
and gives a comprehensive overview of the physics offailure.
• Part II presents all relevant methods and techniques for diagnostics
andmonitoring:fromstress,strain,vibrationanalysis,nondestructive
evaluation, thermography and industrial radiology to computed
tomography and subsurface microstructural analysis.
• PartIIIcorestheprinciplesandconceptsoftechnicalfailureanalysis,
illustrates case studies, and outlines machinery diagnostics with an
emphasis on tribological systems.
• Part IV describes the application of structural health monitoring and
performancecontroltoplantsandtechnicalinfrastructures,including
buildings, bridges, pipelines, electric power stations, offshore wind
structures, and railway systems.
• Part V is an excursion on diagnostics in arts and culture.
IthankDr.WernerDaumandDr.WolfgangHabelandtheteamof
scientists and engineers of BAM (German Federal Institute for Mate-
rials Research and Testing) who helped to create the concept of this
handbook and who authored chapters in all parts of it.
The book integrates knowledge of basic sciences and engineering
disciplines with contributions from research institutions, academe, and
industry,writtenbyinternationallyknownexpertsfromvariouspartsof
the world, including Europe, Canada, India, Japan, and the US. I am
very grateful to all colleagues for their excellent contributions, and
Springerforpublishingthisinternationalinterdisciplinarywork—which
may help to make the world safer.
Berlin, July 2012 Horst Czichos
v
Contents
Part I Introduction
1 Scope of Technical Diagnostics . . . . . . . . . . . . . . . . . . . . . 3
Horst Czichos
2 Application of Technical Diagnostics. . . . . . . . . . . . . . . . . 11
Horst Czichos
3 Physics of Failure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Horst Czichos
Part II Methods and Techniques for Diagnostics
and Monitoring
4 Overview of Diagnostics and Monitoring Methods
and Techniques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Baldev Raj and B. Venkatraman
5 Stress and Strain Determination. . . . . . . . . . . . . . . . . . . . 69
Thomas Kannengiesser and Klaus-Peter Gründer
6 Modal Analysis. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
Werner Rücker
7 Vibration Analysis: Methods and Applications . . . . . . . . . 121
J. Lyle Bagley
8 Acoustic Emission. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
Jürgen Bohse
9 Non-destructive Evaluation. . . . . . . . . . . . . . . . . . . . . . . . 161
Anton Erhard
10 Infrared Thermography . . . . . . . . . . . . . . . . . . . . . . . . . . 175
Clemente Ibarra-Castanedo and Xavier P. V. Maldague
vii
viii Contents
11 Industrial Radiology. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 221
Uwe Ewert, Gerd-Rüdiger Jaenisch, Uwe Zscherpel,
Kurt Osterloh and Bernhard Redmer
12 Computed Tomography . . . . . . . . . . . . . . . . . . . . . . . . . . 249
Jürgen Goebbels
13 Embedded Sensors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 259
Werner Daum
14 Micro-Diagnostics: X-ray and Synchrotron Techniques . . . 287
B. R. Müller and M. P. Hentschel
15 Surface Chemical Analysis at the Micro-
and NanoScale . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 301
Wolfgang E. S. Unger and Vasile-Dan Hodoroaba
16 Sub-Surface Microstructural Analysis. . . . . . . . . . . . . . . . 323
Werner Österle
Part III Technical Diagnostics of Machines and Plants
17 Principles and Concepts of Technical Failure Analysis. . . . 341
Thomas Boellinghaus
18 Failure Analysis: Case Studies . . . . . . . . . . . . . . . . . . . . . 355
Christian Klinger
19 Machinery Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . 387
Richard S. Cowan and Ward O. Winer
Part IV Structural Health Monitoring
and Performance Control
20 Principles, Concepts and Assessment of Structural
Health Monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 413
Werner Daum
21 Buildings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 425
Akira Mita
22 Bridges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 429
Helmut Wenzel
23 Pipelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 453
Daniele Inaudi
Contents ix
24 Electric Power Stations and Transmission Networks . . . . . 471
Wolfgang Habel and Gerd Heidmann
25 Offshore Wind Structures. . . . . . . . . . . . . . . . . . . . . . . . . 505
Claus Kupferschmidt, Mareike Strach, Holger Huhn
and Fabian Vorpahl
26 Railway Systems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 519
L. Quiroga and E. Schnieder
27 Guidelines for Structural Health Monitoring. . . . . . . . . . . 539
Werner Daum
Part V Excursion
28 Diagnostics in Arts and Culture . . . . . . . . . . . . . . . . . . . . 545
Oliver Hahn
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 557
Part I
Introduction
1
Scope of Technical Diagnostics
Horst Czichos
Fault (FR Panne, DE Fehlzustand): the condi-
1.1 Meaning and Impact
tion of an item that occurs when one of its
of Diagnostics
components or assemblies degrades or
exhibits abnormal behavior.
The word diagnostics originates from the med-
Failure (FR Defaillance, DE Ausfall): the ter-
ical field and refers to the identification of the
mination of the ability of an item to perform
nature of a health problem and its classification
a required function. (Failure is an event as
by examination and evaluation. The term diag-
distinguished from fault, which is a state.).
nostic criteria designates the combination of
The failure mode is the phenomenon by
signs, symptoms, and test results to be used in
which a failure is observed. After a failure,
attempts to determine the problem. Diagnosis is
the systematic examination of an item in
the result of a diagnostics process (Fig. 1.1).
order to identify the failure mode and deter-
TECHNICAL DIAGNOSTICS is the examination of mine the failure mechanism and its basic
symptoms and syndromes to determine the nat-
cause is called root cause failure analysis.
ure offaults or failures of technical objects [1].
The identification of faults and failures are
• Asymptomisaperception,madebymeansof
important tasks of technical diagnostics. This
humanobservationsandmeasurements,which
can be illustrated by examples of failure char-
may indicate the presence of an abnormal
acteristics, defined in international standards
condition with a certain probability.
from various technology areas and industrial
• A syndrome is a group of symptoms that
branches [2]. A failure, to be detected by tech-
collectively indicate or characterize an
nical diagnostics, can be:
abnormal condition.
• Termination of the ability of a structure to
The terms fault and failure are defined as
perform its required function when one or
follows [1]:
moreofthecomponentsofastructureareina
defective condition, either at a service or
ultimate limit state.
Mechanical vibration and shock (ISO
ThisintroductorychapteroftheHandbookoutlinesthe 16587).
meaningandimpactofdiagnostics,definesitsbasic • Loss ofthe abilityofabuildingor itsparts to
termsandgivesanoverviewofconcepts,methodsand
perform a specified function.
techniques.
Buildings and constructed assets (ISO
H.Czichos(&) 15686).
BeuthHochschulefürTechnik, • Premature malfunction or breakdown of a
LuxemburgerStraße20a,13353Berlin,Germany
function ora component or the whole engine.
email:[email protected]
H.Czichos(ed.),HandbookofTechnicalDiagnostics, 3
DOI:10.1007/9783642258503 1,(cid:2)SpringerVerlagBerlinHeidelberg2013
4 H.Czichos
Fig.1.1 Theobjectofmedicaldiagnosticsandexamplesofobjectsoftechnicaldiagnostics
Internal combustion engines (ISO 2710). • Anyleakageorjointseparation,unlessotherwise
• Sudden and unexpected ending of the ability determinedtobeduetoapipeorfittingdefect.
of a component or equipment to fulfill its Ships and marine technology (ISO 15837).
function. • Termination of the ability of an item to per-
Gas turbines (ISO 3977). form a required function.
• Actual condition of an item which does not Space systems (ISO 14620).
perform its specified function under the • Systemstatewhichresultsinnon-performance
specified condition. orimpairedperformanceasaresultofahard-
Earth-moving machinery (ISO 8927). wareorsoftwaremalfunction.
• Event causing the loss or reduction of the Road vehicles (ISO 17287).
nominal serviceability. • Insufficient load-bearing capacity or inade-
Cranes (ISO 11994). quateserviceabilityofastructureorstructural
• Loss of structural integrity and/or transmis- element.
sion offluid through the wall of a component Reliability for structures (ISO 2394).
or a joint. These examples from the different techno-
Petroleum and natural gas industries (ISO logical areas and industrial sectors show that
14692). various faults and failures may detrimentally
• State at which a component reaches the influence technical items. Damage identification
threshold level or terminates its ability to by technical diagnostics has to consider gener-
perform a required function. ally four basic aspects:
Hydraulic fluid power (ISO/TR 19972). • the existence of damage,
• Occurrence of bursting, leaking, weeping or • damage location,
pressure loss. • damage type,
Plastics piping systems (ISO 7509). • damage severity.
