Skip to main content

Advertisement

SpringerLink
Log in

Detection of Crack Initiation and Propagation in Aluminum Alloy Under Tensile Loading, Comparing Signals Acquired by Acoustic Emission and Vibration Sensors

  • Published:
Journal of Nondestructive Evaluation Aims and scope Submit manuscript

Abstract

The application of aluminum alloys in various industries such as automotive and aerospace, is inclusive. In addition, in these industries, holes in these materials are used for bolts and rivets. Accordingly, in this article, the initiation and the propagation of cracks in the 2024 aluminum alloy were detected, by means of two methods including acoustic emission and vibration analysis approaches. For this objective, acoustic and vibration sensors were connected to the open-hole aluminum specimen under tensile loading and signals were acquired. Obtained results indicated that the energy of signals, which was recorded by sensors, was comparable to the stress–strain diagram and therefore, the efficiency of two methods in detecting the crack initiation was proved. The calculated maximum stress at the specimen edge by the vibration analysis was closer to experimental data, in comparison to the acoustic emission approach. Then, the fracture frequency of the aluminum alloy was calculated using two mentioned methods and by the fast Fourier transform. By the use of the cumulative energy, which was calculated from recorded signals, the crack propagation was also detected by both approaches and a better efficiency for predicting the fracture by the acoustic emission method was shown. At the end, images of the scanning electron microscopy from the crack and the fracture surface were also demonstrated.

This is a preview of subscription content, log in via an institution to check access.

Access this article

Log in via an institution

Price excludes VAT (USA)
Tax calculation will be finalised during checkout.

Instant access to the full article PDF.

Institutional subscriptions

Fig. 1
Fig. 2
Fig. 3
Fig. 4
Fig. 5
Fig. 6
Fig. 7
Fig. 8
Fig. 9
Fig. 10
Fig. 11

Similar content being viewed by others

References

  1. Mathers, G.: The Welding of Aluminum and its Alloy. Woodhead Publishing, Cambridge (2002)

    Google Scholar 

  2. Khazaee, M., Ahmadi, H., Omid, M., Moosavian, A., Khazaee, M.: Classifier fusion of vibration and acoustic signals for fault diagnosis and classification of planetary gears based on Dempster–Shafer evidence theory. Proc. Inst. Mech. Eng. Part E 228(1), 21–32 (2014)

    Google Scholar 

  3. Grosse, C.U., Masayasu, O.: Acoustic Emission Testing. Springer, New York (2008)

    Google Scholar 

  4. Baydar, N., Ball, A.: A comparative study of acoustic and vibration signals in detection of gear failures using Wigner–Ville distribution. Mech. Syst. Signal Process. 15(6), 1091–1107 (2001)

    Google Scholar 

  5. Saxena, A., Saad, A.: Evolving an artificial neural network classifier for condition monitoring of rotating mechanical systems. Appl. Soft Comput. 7(1), 441–454 (2007)

    Google Scholar 

  6. Rafiee, J., Arvani, F., Harifi, A., Sadeghi, M.H.: Intelligent condition monitoring of a gearbox using artificial neural network. Mech. Syst. Signal Process. 21(4), 1746–1754 (2007)

    Google Scholar 

  7. Cousland, K., Scala, C.M.: Acoustic emission during the plastic deformation of aluminum alloys 2024 and 2124. Mater. Sci. Eng. 57, 23–29 (1983)

    Google Scholar 

  8. Blanchette, Y., Dickson, J.I., Bassim, M.N.: Acoustic emission behavior crack growth of 7075-T651 Al alloy. Eng. Fract. Mech. 24(5), 647–656 (1986)

    Google Scholar 

  9. Yang, D., Wang, J., Li, D., Kuang, K.S.C.: Fatigue crack monitoring using plastic optical fiber sensor. Procedia Struct. Integr. 5, 1168–1175 (2017)

    Google Scholar 

  10. Sayar, H., Alizadeh, M., Azadi, M., Ghasemi-Ghalebahman, A., Jafari, S.M.: Investigation of crack growth behavior in aluminum alloy under low-cycle fatigue loading using a acoustic emission method. In: 26th Annual International Conference of Iranian Society of Mechanical Engineers, Semnan, Iran, April 24–26, 2018

  11. Sayar, H., Alizadeh, M., Azadi, M., Ghasemi-Ghalebahman, A., Jafari, S.M., Mafi, A.: Investigation of crack growth behavior in aluminum alloy used in engine components, by acoustic emission method. J. Engine Res. 48, 3–12 (2017)

    Google Scholar 

  12. Chai, M., Zhang, J., Zhang, Z., Duan, Q., Cheng, G.: Acoustic emission studies for characterization of fatigue crack growth in 316LN stainless steel and welds. Appl. Acoust. 126, 101–113 (2017)

    Google Scholar 

  13. Rivera, F.G., Edwards, G., Eren, E., Soua, S.: Acoustic emission technique to monitor crack growth in a mooring chain. Appl. Acoust. 139, 156–164 (2018)

    Google Scholar 

  14. Hao, Q., Zhang, X., Wang, K., Shen, Y., Wang, Y.: A signal-adapted wavelet design method for acoustic emission signals of rail cracks. Appl. Acoust. 139, 251–258 (2018)

    Google Scholar 

  15. Bruzelius, K., Mba, D.: An initial investigation on the potential applicability of acoustic emission to rail track fault detection. NDT&E Int. 37, 507–516 (2004)

    Google Scholar 

  16. Jomdecha, C., Prateepasen, A., Kaewtrakulpong, P.: Study on source location using an acoustic emission system for various corrosion types. NDT&E Int. 40, 584–593 (2007)

    Google Scholar 

  17. Toutountzakis, T., Tan, C.K., Mba, D.: Application of acoustic emission to seeded gear fault detection. NDT&E Int. 38, 27–36 (2005)

    Google Scholar 

  18. Abdulkarem, W., Amuthakkannan, R., Al-Raheem, K.F.: Centrifugal pump impeller crack detection using vibration analysis. In: 2nd International Conference on Research in Science, Engineering and Technology, Dubai, UAE, March 21–22, 2014

  19. Li, Z., Ma, Z., Liu, Y., Teng, W., Jiang, R.: Crack fault detection for a gearbox using discrete wavelet transform and an adaptive resonance theory neural network. J. Mech. Eng. 61(1), 63–73 (2015)

    Google Scholar 

  20. Moosavian, A., Najafi, G., Ghobadian, B., Mirsalim, M.: The effect of piston scratching fault on the vibration behavior of an IC engine. Appl. Acoust. 126, 91–100 (2017)

    Google Scholar 

  21. Bhalla, S., Soh, C.K.: High frequency piezoelectric signatures for diagnosis of seismic/blast induced structural damages. NDT&E Int. 37, 23–33 (2004)

    Google Scholar 

  22. Loutridis, S., Douka, E., Hadjileontiadis, L.J.: Forced vibration behavior and crack detection of cracked beams using instantaneous frequency. NDT&E Int. 38, 411–419 (2005)

    Google Scholar 

  23. Eftekharnejad, B., Addali, A., Mba, D.: Shaft crack diagnostics in a gearbox. Appl. Acoust. 73, 723–733 (2012)

    Google Scholar 

  24. Barelli, L., Bidini, G., Buratti, C., Mariani, R.: Diagnosis of internal combustion engine through vibration and acoustic pressure non-interasive measurement. Appl. Therm. Eng. 29, 1707–1713 (2009)

    Google Scholar 

  25. Chandroth, G., Sharkey, A., Sharkey, N.: Cylinder pressures and vibration in internal combustion engine condition monitoring. Proc. Comadem 99, 294–297 (1999)

    Google Scholar 

  26. ASTM D5766/D5766M-11: Standard Test Method for Open-hole Strength of Polymer Matrix Composite Laminates. ASTM International, West Conshohocken, PA (2011)

  27. Metals Handbook: Volume 2, Properties and Selection: Nonferrous Alloys and Special-Purpose Materials. ASM International (1990)

  28. Okafor, C., Natarajan, S.: Acoustic emission monitoring of tensile testing of corroded and un-corroded clad aluminum 2024-T3 and characterization of effects of corrosion on AE source events and material tensile properties. AIP Proc. 58, 492–500 (2014)

    Google Scholar 

  29. ASTM E976-10: Standard Guide for Determining the Reproducibility of Acoustic Emission Sensor Response. ASTM International (2010)

  30. Beattie, A.G.: Acoustic emission, principles and instrumentation. J. Acoust. Emiss. 2, 95–128 (1983)

    Google Scholar 

  31. ISO 12716: Nondestructive Testing-Acoustic Emission Inspection: Vocabulary (2001)

  32. Nakamura, H., Ohtsu, M., Enoki, M., Mizutani, Y., Shigeishi, M., Inaba, H., Nakano, M., Shiotani, T., Yuyama, S., Sugimoto, S.: Practical Acoustic Emission Testing. Springer, Berlin (2016)

    Google Scholar 

  33. Sujatha, C.: Vibration and Acoustics Measurement and Signal Analysis. McGraw Hill, London (2010)

    Google Scholar 

  34. Rao, K.R., Kiml, D.N., Hwang, J.J.: Fast Fourier Transform: Algorithms and Applications. Springer, Berlin (2010)

    Google Scholar 

  35. Roberts, T.M., Talebzadeh, M.: Acoustic emission monitoring of fatigue crack propagation. J. Constr. Steel Res. 59, 695–712 (2003)

    Google Scholar 

  36. Bassim, M.N., Lawrence, S.S., Liu, C.D.: Detection of the onset of fatigue crack growth in rail steels using acoustic emission. Eng. Fract. Mech. 47(2), 207–214 (1994)

    Google Scholar 

  37. Harris, D.O., Dunegan, H.L.: Continuous monitoring of fatigue-crack growth by acoustic-emission techniques. Exp. Mech. 14, 71–81 (1974)

    Google Scholar 

  38. Shigley, J.E., Mischkle, C.R.: Standard Hand book of Machine Design. McGraw Hill, London (1986)

    Google Scholar 

  39. Pilkey, W.D.: Peterson’s Stress concentration Factors. Wiley, New York (1997)

    Google Scholar 

  40. Howland, R.C.J.: On the stresses in the neighborhood of a circular hole in a strip under tension. Philos. Trans. R. Soc. Lond. Ser. A 229, 49–86 (1930)

    MATH  Google Scholar 

  41. Young, W.C., Budynas, R.G.: Roark’s Formulas for Stress and Strain, 7th edn. McGraw Hill, London (2001)

    Google Scholar 

  42. Ennaceur, C., Laksimi, A., Herve, C., Cherfaoui, M.: Monitoring crack growth in pressure vessel steels by the acoustic emission technique and the method of potential difference. Int. J. Press. Vessels Pip. 83, 197–204 (2006)

    Google Scholar 

  43. Khazaee, M., Ahmadi, H., Omid, M., Banakar, A., Moosavian, A.: Feature-level fusion based on wavelet transform and artificial neural network for fault diagnosis of planetary gearbox using acoustic and vibration signals. Insight Non-Destruct. Test. Cond. Monit. 55(6), 323–330 (2013)

    Google Scholar 

  44. Khazaee, M., Ahmadi, H., Omid, M., Moosavian, A., Khazaee, M.: Classifier fusion of vibration and acoustic signals for fault diagnosis and classification of planetary gears based on dempster-shafer evidence theory. Proc. Inst. Mech. Eng. Part E 228(1), 21–32 (2014)

    Google Scholar 

  45. Chen, J., Yuan, X., Hu, Z., Li, T., Wu, K., Li, C.: Improvement of resistance-spot-welded joints for DP 600 steel and A5052 aluminum alloy with Zn slice interlayer. J. Manuf. Process. 30, 396–405 (2017)

    Google Scholar 

  46. Tocci, M., Pola, A., Montesano, L., Merlin, M., Garagnani, G.L., La Vecchia, G.M.: Tensile behavior and impact toughness of an AlSi3MgCr alloy. Procedia Struct. Integr. 3, 517–525 (2017)

    Google Scholar 

  47. Bobbili, R., Madhu, V., Gogia, A.K.: Tensile behavior of aluminum 7017 alloy at various temperatures and strain rates. J. Mater. Res. Technol. 5(2), 190–197 (2016)

    Google Scholar 

  48. Ma, H., Huang, L., Tian, Y., Li, J.: Effects of strain rate on dynamic mechanical behavior and microstructure evolution of 5A02-O aluminum alloy. Mater. Sci. Eng. A 606, 233–239 (2014)

    Google Scholar 

Download references

Acknowledgements

Authors should thank Irankhodro Powertrain Company (IPCo.) for the financial support and providing the equipment for the acoustic emission approach and the vibration analysis. Authors also tend to have a special thanks to Dr. S.M. Jafari and Dr. A. Moosavian, for their guidance.

Author information

Authors and Affiliations

  1. Faculty of Mechanical Engineering, Semnan University, Semnan, Iran

    Hassan Sayar & Mohammad Azadi

  2. Faculty of Aerospace Engineering, Semnan University, Semnan, Iran

    Mohsen Alizadeh

Authors
  1. Hassan Sayar
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. Mohammad Azadi
    View author publications

    You can also search for this author in PubMed Google Scholar

  3. Mohsen Alizadeh
    View author publications

    You can also search for this author in PubMed Google Scholar

Corresponding author

Correspondence to Mohammad Azadi.

Additional information

Publisher's Note

Springer Nature remains neutral with regard to jurisdictional claims in published maps and institutional affiliations.

Rights and permissions

Reprints and permissions

About this article

Check for updates. Verify currency and authenticity via CrossMark

Cite this article

Sayar, H., Azadi, M. & Alizadeh, M. Detection of Crack Initiation and Propagation in Aluminum Alloy Under Tensile Loading, Comparing Signals Acquired by Acoustic Emission and Vibration Sensors. J Nondestruct Eval 38, 100 (2019). https://doi.org/10.1007/s10921-019-0639-9

Download citation

  • Received:

  • Accepted:

  • Published:

  • DOI: https://doi.org/10.1007/s10921-019-0639-9

Keywords

Search

Navigation