Nondestructive Materials Characterization: With Applications to Aerospace Materials

435 Pages·2004·13.8 MB·English

by  N. Meyendorf

Springer Series in
MATERIALS SCIENCE
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Editors: R. Hull R. M. Osgood, Jr. J. Parisi H. Warlimont
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62 Epitaxy 67 Nondestructive
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Norbert G.H. Meyendorf
Peter B. Nagy
Stanislav I. Rokhlin
(Eds.)
Nondestructive
Materials
Characterization
With Applications
to Aerospace Materials
With Figures and Tables
311 11
" Springer
Professor Norbert G.H. Meyendorf Professor Peter B. Nagy
University of Dayton University of Cincinnati
Center for Materials Diagnostics Dept. of Aerospace Engineering
300 College Park and Engineering Mechanics
Dayton, OH 45469-0121, USA MLo070, Cincinnati, OH 45221, USA
E-mail: [email protected] E-mail: [email protected]
Professor Stanislav I. Rokhlin
The Ohio State University
Dept. of Industrial, Welding
and Systems Engineering
1248 Arthur E. Adams Drive
Columbus, OH 43221, USA
E-mail: [email protected]
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University of Virginia Universität Oldenburg, Fachbereich Physik
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Charlottesville, VA 22903-2442, USA 26129 Oldenburg, Germany
Professor R. M. Osgood, Jr. Professor Hans Warlimont
Microelectronics Science Laboratory Institut für Festkörper-
Department of Electrical Engineering und Werkstofforschung,
Columbia University Heimholtzstrasse 20
Seeley W. Mudd Building 01069 Dresden, Germany
New York, NY 10027, USA
ISSN 0933-033X
ISBN 978-3-642-07350-2 ISBN 978-3-662-08988-0 (eBook)
DOI 10.1007/978-3-662-08988-0
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Preface
Nondestructive Evaluation (NDE) becomes a key discipline for modem
technology. Information about materials defects and properties is significant to
guarantee reliability of a product and avoid fatal accidents. For instance
technologies with high safety requirements like aviation, automotive, and energy
production are driving forces for NDE. Keeping in mind that aging of the
infrastructure is an issue in all industrial countries and that, for example, an
aircraft can have a lifetime of several decades poses new challenges for NDE and
especially nondestructive materials characterization. Besides the traditional in
field applications, NDE becomes more and more a tool to study materials
degradation processes and to provide engineers with input data for sophisticated
models describing materials behavior and the life of components. At present, this
marriage of NDE and materials modeling shows significant success in predicting
damage progression (corrosion, fatigue) and thus an enhancement of availability
and reliability of components and complete aircraft.
This book will give a snapshot of the present research in materials
characterization of aging aircraft. Methods considered are x-ray, ultrasonic, optical
and thermal techniques and in particular techniques with high spatial resolution to
detect and quantify early stages of degradation or to characterize materials
microstructure. Every chapter briefly describes the basics and the principles of one
NDE method under consideration. Discussing recent research results by applying
these methods completes the chapters. The readers will get an overview of the
present state of the art of materials characterization techniques. The book shows a
unique summary of NDE methods applied to similar materials under examination.
This allows the reader to understand the advantages and disadvantages of several
techniques and will help to find approaches to solve NDE materials
characterization problems.
However, the present book can summarize only a limited number of NDE
approaches for materials characterization. This overview cannot be complete. For
example electromagnetic methods that have significant importance not only for
aviation but also in many other industries like automotive, energy, steel making
have been completely excluded. The applications discussed in this volume are
focused on aluminum and titanium alloys and polymer coatings. The size of the
book did not allow the consideration of ferromagnetic materials, ceramic, and
composite materials that have high importance for aircraft structures and
elsewhere that are challenging for NDE as weIl. A second volume will be required
to complete this overview.
VI Preface
The accomplishments presented in this volume where not possible without
strong financial, technical, and administrative support. The editors gratefully
acknowledge, The United States Air Force Office of Scientific Reserch, The State
of Ohio, The National Science Foundation, The Air Force Research Laboratory at
Wright-Patterson Air Force Base, The Fraunhofer Society, The University of
Dayton Research Institute, The University of Dayton, The Ohio State University,
and The University of Cincinnati for their support. Lt. Col. Paul Trulove, Dr.
Hugh DeLong, Dr. Thomas Moran and Dr. Theodore Matikas are personally
acknowledged for their significant impact on the results presented in this book.
Finally we would like to thank Dr. George Y. Baaklini, NASA Glenn Research
Center, Dr. Thomas Moran, Air Force Research Laboratories, Wright Patterson
Air Force Base, Gerald S. Frankei, The Ohio State University, Robert G. Andrews
and Dr. Theodore Nicholas, University of Dayton Research Institute for critical
reviewing the manuscripts.
Dayton, Ohio, April 2003 Norbert G.R. Meyendorf
Peter B. Nagy
Stanislav I. Rokhlin
Contents
1 Degradation of Aircraft Structures ......................................................... 1
1.1 Introduction ................. ....... ..... .... ...... .... .......... ....... ... .... ...... .......... ...... ........ 1
1.2 NDE Methods at a Glance........................................................................... 2
1.3 Degradation of Aircraft Materials and NDE ............................................... 5
1.3.1 Corrosion Protective Coatings ....................................................... 5
1.3.2 Corrosion ........................................................................................ 9
1.3.3 Fatigue ............................................................................................ 15
1.3.4 Freuing and Fretting Fatigue .......................................................... 21
1.4 Introduction to the Next Chapters ............................................................... 23
References ............................................................................................................. 24
2 Optical Detection of Surface Damage ...................................................... 26
2.1 Introduction ................................................................................................. 26
2.2 Background ................................................................................................. 27
2.3 Instrumentation and Method ....................................................................... 28
2.4 Applications ................................................................................................ 29
2.4.1 Optical Quantification of FreUing Fatigue Damage ....................... 30
2.4.2 Characterization of Localized Corrosion Damage
and Its Role for Fatigue Crack Initiation ........................................ 37
2.4.3 Characterization of Crack Damage States
in Titanium Alloys through Examination
of the Surface Deformation Preceding the Crack Front ................. 47
2.4 Conc1usions ................................................................................................. 55
References ............................................................................................................. 56
3 Microradiographic and Foil Penetration Methods
for Quantification of LocaIized Corrosion .............................................. 58
3.1 Introduction ................................................................................................. 58
3.2 Background ................................................................................................. 59
3.3 Microradiographic System .......................................................................... 61
VIII Contents
3.4 Microradiographie Methods ..... ..................................................... ............ 63
3.4.1 Microradiographic Methods Evaluation....................................... 63
3.4.2 Microradiography of Corrosion Samples ..................................... 74
3.4.3 Mieroradiographie Methods for Pit Depth Measurement ............ 76
3.4.4 Validation of Mieroradiographic Pit Depth Measurement........... 79
3.4.5 Mieroradiographic Characterization of Fatigue Cracks Initiated
by Corrosion Pits.......................................................................... 91
3.4.6 Phase-Contrast Image Enhancement with Microradiography ...... 95
3.5 Foil Penetration Method........ ................ .... ........ ........ ................................ 99
3.6 Applicationof Mieroradiography for Studying Localized Corrosion ....... 101
3.6.1 Mieroradiographic Analysis
of Corroded Foil Penetration Samples ......................................... 101
3.6.2 In Situ Mieroradiography of Localized Corrosion Growth .......... 105
3.7 Summary and Conclusions ........................................................................ 110
References ........................................................................................................... 112
4 Interferometric and Holographie Imaging of Surface Wave Patterns
for Characterization of Material Degradation ..................................... 113
4.1 Introduction ............................................................................................... 113
4.2 Background ............................................................................................... 114
4.2.1 Ultrasonie Nondestructive Evaluation (NDE) .............................. 114
4.2.2 Surface Acoustic Waves (SA W) .................................................. 116
4.2.3 U1trasonic Reflection and Scattering from Microcracks .............. 119
4.2.4 Loca1 Ultrasonie Scattering from Surface-Breaking Cracks ........ 122
4.2.5 Optical Interferometry and Holography ....................................... 125
4.3 Instrumentation and Methods .................................................................... 127
4.3.1 Near-Field Scanning Interferometry (NFSI) System ................... 127
4.3.2 Frequency Translated Holography (FTH) System ....................... 128
4.4 Applications .............................................................................................. 128
4.4.1 Interferometric and Holographie Imaging of Surface Waves ...... 130
4.4.2 Local Ultrasonic Scattering from Surface-Breaking Cracks ........ 131
4.4.3 Crack-Depth Determination ......................................................... 133
4.4.4 In Situ Stress-Corrosion Crack (SCC) Growth Measurements .... 136
4.5 Future Trends ............................................................................................ 139
References ........................................................................................................... 140
5 Surface Acoustic Wave Characterization
of Pitting Corrosion Damage with Fatigue Crack .......................••.•..... 142
5.1 Introduction ............................................................................................... 142
5.2 Background ............................................................................................... 144
Contents IX
5.3 Instrumentation and Methods .................................................................... 145
5.3.1 Experiments ................................................................................. 145
5.3.2 Fatigue Crack Growth Analysis ................................................... 147
5.3.3 Analysis of Surface Wave Scattering for Crack Sizing ................ 152
5.4 Applications .............................................................................................. 157
5.4.1 Pit Size Measurements ................................................................. 157
5.4.2 Ultrasonic Sizing of Crack Initiated from a Pit.. .......................... 160
5.4.3 Fatigue Life Prediction ................................................................. 172
5.5 Future Trends ............................................................................................ 176
References ........................................................................................................... 177
6 Ultrasonic Fatigue Crack Detection in Aluminum
and Titanium Alloys ..••.•.•.••••.•.•.••.•.•••...••...•.•.••.•...•.•..•.•.•.•.•.•.•••...••••........ 180
6.1 Introduction ............................................................................................... 180
6.2 Background (Crack-Closure) .................................................................... 182
6.3 Instrumentation and Methods .................................................................... 185
6.3.1 Thermo-Optical Modulation ........................................................ 185
6.3.2 The Role ofThermal Diffusivity .................................................. 187
6.4 Applications .............................................................................................. 193
6.4.1 Dynamic Thermo-Optical Modulation in AI-2024 ....................... 193
6.4.2 Quasi-static Thermo-Optical Modulation in Ti-6AI-4V .............. 198
6.5 Condusions ............................................................................................... 204
References ........................................................................................................... 205
7 Early Detection of Fatigue Damage in Ti-6AI-4V
with Nonlinear Acoustics •.••••••••••...•.•....•••.••..•.••..•••....•.•..•.....•.........•.•....• 206
7.1 Introduction ............................................................................................... 206
7.2 Background ............................................................................................... 207
7.2.1 Linear Acoustic Measurements and Fatigue ................................ 207
7.2.2 Nonlinear Acoustics in Fatigue Damage Measurement ............... 207
7.3 Methods ..................................................................................................... 209
7.3.1 General Description ..................................................................... 209
7.3.2 Capacitive Detector Method ......................................................... 210
7.3.3 Piezoelectric Method .................................................................... 213
7.3.4 In Situ Measurement .................................................................... 214
7.4 Applications .............................................................................................. 216
7.4.1 Material and Sampie Description ................................................. 216
7.4.2 Interrupted Fatigue Measurements (Low Cyde Fatigue) ............. 217
7.4.3 In Situ Measurements ................................................................... 220