Metody nieniszczące w ocenie rozwoju uszkodzenia materiałów konstrukcyjnych w warunkach obciążeń eksploatacyjnych

• Autorzy: Kukla Dominik

Warianty tytułu

EN

Non-destructive methods in assessment of damage development in structural materials operated under service loads

• Języki publikacji: PL

Abstrakty

PL

Praca dotyczy wykorzystania metody prądów wirowych oraz innych metod nieniszczących do identyfikacji lokalnych zmian w strukturze materiału związanych z rozwojem uszkodzenia w warunkach obciążenia zmęczeniowego. Dla wybranych, metalicznych materiałów konstrukcyjnych (stale, stopy niklu i aluminium) poddanych cyklicznym obciążeniom zmiennym opracowano ilościowe charakterystyki rozwoju uszkodzenia na podstawie wyznaczonych zmian składowych odkształcenia w kolejnych cyklach obciążenia. Równocześnie z próbami zmęczeniowymi przetestowano szereg diagnostycznych metod nieniszcząych w celu oceny możliwości lokalizacji procesu inicjowania uszkodzenia zmęczeniowego w materiale próbek. Opracowane procedury badawcze z zastosowaniem metody prądów wirowych, wspierane technikami optycznymi (lub innymi technikami NDT), umożliwiły nie tylko identyfikację obszarów uszkodzenia zmęczeniowego we wczesnym etapie rozwoju, związanego ze zmianami strukturalnymi, ale także na monitorowanie procesu degradacji próbek, aż do ich zerwania. Badania przeprowadzono na stopach konstrukcyjnych dobranych nie tylko z uwagi na właściwości elektromagnetyczne, ale przede wszystkim na mechanizmy rozwoju uszkodzenia zmęczeniowego. Badania próbek z żarowytrzymałej stali 1.4903 obejmowały testy zmęczeniowe wraz z wyznaczeniem odkształceniowego współczynnika uszkodzenia zmęczeniowego (φ) opisującego dynamikę zmian składowych odkształcenia w kolejnych cyklach obciążeń zmiennych. Wyniki tych obliczeń skorelowano z wynikami pomiarów parametru sygnału prądowirowego w postaci kąta fazowego krzywej impedancyjnej, realizowanych według opracowanej procedury. Pomiar ten wykonano w zdefiniowanych miejscach na próbce poddanej obciążeniom zmiennym, po ustalonej liczbie cykli zmęczeniowych. Przeprowadzono także badania mikrostrukturalne w zakresie metalografii (zgładów poprzecznych i podłużnych) oraz fraktografii (przełomów) próbek poddanych próbom zmęczeniowym. Badania mikrostrukturalne potwierdziły występowanie zjawisk związanych z degradacją zmęczeniową, które mogą uzasadniać zmiany charakterystyki sygnału prądowirowego w funkcji jej rozwoju. Zjawiska te to przede wszystkim lokalne odkształcenia plastyczne wokół twardych wtrąceń oraz mikropęknięcia. Badania zmęczeniowe dla stali 1.4903 przeprowadzono na próbkach w stanie dostawy oraz na próbkach eksploatowanych w warunkach pracy rurociągów pary świeżej w jednej z krajowych elektrowni. Na podstawie analizy uzyskanych wyników badań i ich obróbki opracowano metodykę oceny rozwoju degradacji wyrażonej ilościowo poprzez narastanie składowych odkształcenia niesprężystego w kolejnych cyklach obciążenia. Na podstawie opracowanych procedur pomiarowych uzyskano wyniki wskazujące zarówno na możliwość lokalizacji i identyfikacji defektów powstałych wskutek procesu zmęczeniowego we wczesnym etapie jego rozwoju, jak i na ilościową ocenę stopnia degradacji na podstawie analizy zmian parametrów wyznaczonych techniką prądów wirowych w kolejnych cyklach obciążeń zmęczeniowych. Kolejne wyniki uzyskano w badaniach stopu niklu MAR 247 stosowanego do budowy łopatek turbin silników lotniczych. Serię próbek z tego stopu poddano próbom zmęczeniowym, którym towarzyszyły badania nieniszczące z wykorzystaniem technik optycznych, takich jak cyfrowa korelacja obrazu (DIC - Digital Image Correlation) czy elektroniczna interferometria plamkowa (ESPI - Electronic Speckle Pattem Interferometry). Na próbkach poddawanych testom zmęczeniowym przeprowadzono także pomiary konduktywności z zastosowaniem metody prądów wirowych (według opracowanej procedury) oraz klasyczne badania defektoskopowe. Metody optyczne pozwoliły na wczesną identyfikację lokalnych koncentracji odkształcenia, wynikających z lokalnych koncentracji naprężenia. Obszary te stanowiły miejsce rozwoju propagacji pęknięcia dominującego, co potwierdziły prowadzone równolegle badania metodą prądów wirowych, które ujawniły także inne pęknięcia zmęczeniowe na etapie poprzedzającym rozwój uszkodzenia dominującego. Ponadto wykazano lokalne zmniejszenie konduktywności w obszarze inicjowania uszkodzenia, związanego z koncentracją odkształcenia. Podobne badania wykonano dla stopu Inconel 718 z zastosowaniem próbek o zmiennej powierzchni przekroju, co umożliwiało uzyskanie zmiennego pola deformacji. Opisano także wyniki badań dotyczących identyfikacji i oceny wad technologicznych oraz eksploatacyjnych związanych m.in z lokalnym przegrzaniem struktury materiału przez narzędzie szlifierskie, niewłaściwie przeprowadzoną obróbkę plastyczną na zimno oraz z oddziaływaniem atmosfery wodorowej. Opracowane procedury badawcze dają możliwość identyfikacji defektów związanych z przypaleniami szlifierskimi, a wykonując analizę parametrów rejestrowanego sygnału impedancji uzyskanego metodą prądów wirowych, można poznać ich właściwości. Dotyczy to ilościowej oceny głębokości strefy przegrzania oraz jakościowej oceny zmian twardości warstwy spowodowanej oddziaływaaniem wysokiej temperatury.

EN

The work concerns the application of eddy current and other non-destructive methods for identification of local changes in the structure of material due to the development of damage under fatigue conditions. For selected, metallic structural engineering materials (steels, nickel and aluminum alloys) subjected to cyclic alternating loads, the quantitative characteristics of damage development were presented and described on the basis of the evolution of deformation components in subsequent load cycles. Along with the fatigue tests, a number of nondestructive diagnostic methods were used to assess the possibility of locating the fatigue failure initiation process in various materials. The proposed research procedures of the eddy current method, supported by optical techniques, allowed not only for early-stage identification of fatigue damage development areas but also to monitor the degradation process of specimens, up to their failure. The eddy current measurements were carried out on alloys selected on the basis of their (magnetic) properties and mechanisms of fatigue damage development. The tests of the heat-resistant steel specimens (1.4903) included fatigue tests with the determination of the deformation fatigue damage factor describing the dynamics of changes in the deformation components in subsequent load cycles. The results of these calculations were correlated with the measurements of the eddy current signal phase angle, carried out according to the developed procedure. This measurement was performed in selected areas on a specimen subjected to variable loads and after a predetermined number of fatigue cycles. Microstructural observations of specimens subjected to fatigue tests were also carried out in the field of metallography (transverse and longitudinal sections) as well as fractography (fractures). Microstructural studies allowed to confirm the occurrence of processes and phenomena related to fatigue degradation, which may justify changes in the values of the eddy current signal parameters (phase angle) as a function of its development. These were mainly local plastic deformations around hard inclusions and microcracks. Fatigue tests for this steel were carried out on specimens in the as-received condition and on the live steam pipelines operated in the power plant. Based on the eddy current analysis, a fatigue life determination methodology was developed. Such methodology considers the development of degradation, expressed quantitatively, through the growth of the deformation components in subsequent cycles. Based on the established measurement procedures, the obtained results indicate the possibility of localization and identification of fatigue damage at an early stage of its development, as well as a quantitative assessment of the degree of degradation based on the eddy current technique. Further investigations were performed on the MAR 247 nickel alloy used in the construction of turbine blades of aircraft engines. A series of specimens were subjected to fatigue tests and simultaneously monitored by non-destructive, optical testing techniques such as Digital Image Correlation (DIC) and Electronic Speckle Pattern Interferometry (ESPI). Subsequent conductivity measurements were performed on such specimens by using the eddy current method (according to the developed procedure), as well as classic defectoscopy tests. Optical techniques enabled an early identification of local strain concentrations resulting from local stress concentrations. In these areas, the development of the dominant crack propagation was observed. Such observations were further confirmed by the parallel eddy current tests, which also revealed other fatigue cracks at the stage preceding the development of the dominant damage. A local drop in the conductivity value in the area of damage initiation was also found in the form of strain concentration. Similar tests were also carried out for the Inconel 718 alloy by using specimens with a variable cross-sectional area enabling to obtain a variable deformation field. Additionally, an attempt to identify technological defects resulting from local overheating of the material structure by the grinding tool was made. The developed test procedures enabled the detection of defects related to grinding burns. The subsequent analysis of the parameters of the recorded impedance signal obtained by the eddy current method, allows the quantitative assessment of the depth of the overheating zone and the qualitative assessment of changes in the hardness of the layer, resulting from the effect of high temperature.

Słowa kluczowe

PL

wytrzymałość materiałów; metody nieniszczące; metoda prądów wirowych; badania prądami wirowymi; materiał konstrukcyjny; stal żarowytrzymała

EN

materials resistance; non-destructive methods; structural material; eddy current method; heat-resistant steel

• Wydawca: Instytut Podstawowych Problemów Techniki PAN
• Czasopismo: IPPT Reports on Fundamental Technological Research
• Rocznik: 2023
• Tom: nr 1
• Strony: 1--168
• Opis fizyczny: Bibliogr. 193 poz., rys.

Twórcy

autor

Kukla Dominik

• Instytut Podstawowych Problemów Techniki Polskiej Akademii Nauk

Bibliografia

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Uwagi

Opracowanie rekordu ze środków MNiSW, umowa nr SONP/SP/546092/2022 w ramach programu "Społeczna odpowiedzialność nauki" - moduł: Popularyzacja nauki i promocja sportu (2024).