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Development of an Acoustic Emission Test Platform with a Biaxial Stress Loading System

Development of an Acoustic Emission Test Platform with a Biaxial Stress Loading System. Progress Report for the Period August 22, 2002 – March 31, 2003. Joseph Oagaro, Shreekanth Mandayam, John L. Schmalzel and Ronnie K. Miller. Electrical & Computer Engineering 201 Mullica Hill Road

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Development of an Acoustic Emission Test Platform with a Biaxial Stress Loading System

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  1. Development of an Acoustic Emission Test Platform with a Biaxial Stress Loading System Progress Report for the Period August 22, 2002 – March 31, 2003 Joseph Oagaro, Shreekanth Mandayam, John L. Schmalzel and Ronnie K. Miller Electrical & Computer Engineering 201 Mullica Hill Road Glassboro, NJ 08028 (856) 256-5333 http://engineering.rowan.edu/ PERF 95-11 STEERING COMMITTEE MEETING Sheraton Seattle Hotel & Towers, Seattle, Washington April 16, 2003

  2. Presentation Outline • Project Objectives • Personnel • Test Specimens • AE Training and Quality Assurance • AE Test Platforms (Design, Development and Results) • Version 1 • Version 2 • Version 3 • Summary and Future Work

  3. Project Objectives • Design and develop test-platforms for performing Acoustic Emission (AE) measurements on defective pipe segments under bi-axial stress conditions • Develop empirical relations between stress and AE signal parameters

  4. Major Tasks • Specimen fabrication • Set-up for 2-D Tensile Testing • Instrumentation (AE and control) and data acquisition set-up • AE testing: collaboration with Physical Acoustics Corporation • Signal analysis

  5. Data Acquisition Signal Conditioning Display/ User Interface Conceptual Design: Test Platform AE Sensors Specimen Load Cell Simulated Defect Double Acting Hydraulic Ram

  6. Test Platform Design Criteria • Design Challenges • Rigid Frame • Biaxial Loading of test specimen • 30,000 psi (45,000 lbs) 1st Dimension • 15,000 psi (22,500 lbs) 2nd Dimension • Short manufacturing time • Low cost

  7. Project Personnel • Rowan • Dr. Shreekanth Mandayam (PI), Dr. John Schmalzel (Co-PI), Joe Oagaro (Senior ECE), Dan Edwards (Senior ME), John Ludes (Junior ECE), Terry Lott (Junior ME) • PAC • Dr. Ronnie K. Miller

  8. Specimen Fabrication • Provided by Shell • 0.5” Thick SA-516 grade 70 Steel Coupons • Simulated Cracks of varying depths • .08”, .16”, and .32” deep • Two sets of 3 specimens each

  9. In-House Specimen Fabrication • ASTM 836 steel specimens • Saw-cut defects (80% deep, 2.5” long) Rowan Water Jet Machining Center

  10. Collaboration with PAC • Rowan personnel were trained on AE system at PAC on August 22, 2002 • 4-Channel AE system was delivered to Rowan on September 26, 2002 • Rowan personnel were trained on system by PAC • Project meeting on January 30, 2003 for reviewing test results; design and test modifications suggested

  11. AE Test Platforms • Version 1 • Prototype Design • 13.5ksi (20,000 lbs) max load • Version 2 • Clamping Bracket Modification • 20,000ksi (30,000 lbs) max load • Version 3 • Hydraulic Rams • Full Desired load of 30ksi (45,000 lbs)

  12. Frame Load Transducer Specimen Loading Screws Specimen Clamping Bracket AE Test Platform: Version 1

  13. FEM Analysis COSMOSWorks FEM analysis of clamping block

  14. AE Test Station Construction: Version 1 1/24/2003

  15. Testing Parameters • Specimen was preloaded to: • Axis 1: 10,000 lbs • Axis 2: 20,000 lbs • AE sensors activated and test run for approximately 30 minutes • Crack Depth 60%, Length 2.5”

  16. AE Results: Version 1

  17. AE Results: Version 1

  18. AE Results: Version 1

  19. AE Location: Version 1

  20. Design Limitations: Version 1 • Clamping method caused deformation of specimen producing spurious AE data. • Location View shows AE Hit concentration in proximity of clamping brackets • Connection from load cell to specimen fixed, causing bending moment and non-uniform loading of specimen • Inability to reach desired load

  21. Frame Load Transducer Specimen Loading Screws Specimen Clamping Bracket AE Test Platform: Version 2 • New Clamping Brackets • Pinned connections for ensure uniform loading • Max load of 30,000 lbs

  22. Testing Parameters • AE sensors active throughout loading of specimen • Specimen loaded in steps of 2000 lbs up to: • Axis 1: 30,000 lbs • Axis 2: 15,000 lbs • Signal processing to remove spurious data during loading of test platform

  23. AE Results: Version 2

  24. AE Results: Version 2

  25. AE Results: Version 2

  26. AE Location: Version 2 COSMOSWorks FEM Model

  27. Why Version 3? • Hydraulic design • Allows for increasing max load to 30 ksi • Controlled loading environment • New clamping bracket • Single pin piece – minimizes noise

  28. Frame Load Transducer Specimen Hydraulic Cylinders Specimen Clamping Bracket AE Test Platform: Version 3

  29. Summary of Progress • Rowan personnel have been trained in AE testing techniques by PAC • Two versions of the biaxial loading test platform constructed – fabrication of third and final version underway • AE tests conducted on test specimens fabricated in-house; specimens provided by Shell will be tested on Version 3 • AE signatures obtained for 1-D and 2-D loading of the test specimens indicate appreciable differences, demonstrating proof-of-concept of the technique • Continuous interaction with PAC for quality assurance.

  30. Future Plans • Develop Version 3 of the test platform withhydraulic loading • Conduct tests on specimens provided by Shell • Parameterize AE signature differences between uni- and bi-axial loading of test specimens • Generate calibration curves and empirical relationships quantifying 1-D and 2-D stress effects • Generate final report summarizing all findings • Provide recommendations for design of a pressure vessel test platform

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