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Remote Detection of Stage II to Stage III
Cracking in Steel Bridge Girder Material

                             M. Hossain



  ASNT 20th Annual Research Symposium & Spring Conference
                     San Francisco, California
                        21-25 March, 2011



This project is sponsored by the U.S. Department of Commerce, NIST-TIP
             (Cooperative Agreement Number 70NANB9H9007)
Background
   S




         Safe area

                          N


da/dN
        unstable cracking
                                critical cracking level


                              Paris Law:
        stable cracking
                              da/dN=C(∆K)m


        threshold

                                           K
                                                          2
Background




                                               Voltage, mV
                                                             Time, μS


Acoustic emission (AE) techniques:
   High sensitivity and reliability
   Capability of locating and quantifying active cracks

                                                                        3
Objective

Bridge Prognostic System
•   Self-Powered
•   Wireless Sensor Network
•   Structural Bridge Health Prognosis


Current tasks
•   Understand mechanism of acoustic emission(AE) corresponding to
    crack growth behavior in the steel bridge material
•   Data interpretation to identify structural damage and deterioration
•   Modeling to assess the remaining fatigue life




                                                                          4
Experimental Procedure



            12.0 in
                                            3.25 in




                      R15I       WDI

                             9.5 in
                                  12.0 in



       AE-monitored fatigue tests:
       Compact tension (CT) specimens, made of A572G50
       MTS 810 hydraulic machine
       Crack growth: clip gage, microscope and fiber light
       AE sensors: R15I 5, WDI 3
       Sensor Highway II-Remote Asset Integrity Monitor
                                                             5
Data Filtering and Reducing Procedures

1. Eliminate AE collected below 80% of peak load


                                                                      Yielding

           2        4                                                 Crack extension
                            Pmax


                                     Y-stress         Crack opening
load




                             Pmean                                      Crack closure
                                                            Grating
       1       3        5
                            Pmin                                Reversed yielding

                   time
                                                                      Y-strain
                                                Stress-strain behavior at crack tip in a load cycle

                                                                                                      6
Data Filtering and Reducing Procedures
                                                                      Counts
2. Friction emission tests to understand
                                             Peak                     Threshold
   characteristics of noise
                                           amplitude
3. Pencil lead break tests to understand
   characteristics of genuine hits
                                               Rise time
                                                           Duration

                               2                                      3




                                                                               7
Data Filtering and Reducing Procedures

4. Swansong Ⅱ filter to minimize mechanical noise




                                                      8
Data Filtering and Reducing Procedures

5. Evaluate quality of filtered AE data




                                                       9
Results and Discussion

1. Sparse dataset

                                4
                               3.5       Hit rate
                                3
                               2.5
                    Hit rate




                                2
                                         10% increase of cyclic loads
                               1.5
                                1
                               0.5
                                0
                                     0       5,000      10,000      15,000   20,000
                                                     Load cycles

                                                                                      10
Results and Discussion

2. Determination of critical cracking level

                                         400,000                                                                   350
                                                        Cumulative absolute energy




                                                                                                                         Maximum stress intensity, MPa√m
                                         350,000
        Cumulative absolute energy, aJ




                                                                                                                   300
                                                        Maximum stress intensity
                                         300,000
                                                                                                                   250
                                         250,000
                                                                                                                   200
                                         200,000
                                                                                                                   150
                                         150,000               10% increase of cyclic loads
                                                                                                                   100
                                         100,000

                                          50,000                                                                   50
                                                                                              critical     level
                                              0                                                                   0
                                                   0   3,000       6,000      9,000      12,000   15,000     18,000
                                                                           Load cycles
                                                                                                                                                           11
Results and Discussion

2. Determination of critical cracking level

                                         16,000,000                                                                    350
                                                           Cumulative signal strength




                                                                                                                             Maximum stress intensity, Mpa√m
       Cumulative signal strength, V-T




                                         14,000,000                                                                    300
                                                           Maximum stress intensity
                                         12,000,000
                                                                                                                       250
                                         10,000,000
                                                                                                                       200
                                          8,000,000
                                                                                                                       150
                                          6,000,000               10% increase of cyclic loads
                                                                                                                       100
                                          4,000,000

                                          2,000,000                                                                    50
                                                                                                 critical      level
                                                 0                                                                     0
                                                      0   3,000      6,000      9,000      12,000     15,000      18,000
                                                                             Load cycles

                                                                                                                                                               12
Results and Discussion

2. Determination of critical cracking level

                         35,000

                         30,000       Cumulative counts
     Cumulative counts




                         25,000

                         20,000
                                               10% increase of cyclic loads
                         15,000

                         10,000

                          5,000
                                                                                critical     level
                             0
                                  0   3,000       6,000        9,000          12,000       15,000    18,000
                                                           Load cycles

                                                                                                              13
Results and Discussion

2. Determination of critical cracking level

                        600                                                                              350
                                  Cumulative hits




                                                                                                               Maximum stress intensity, MPa√m
                        500                                                                              300
                                  Maximum stress intensity
                                                                                                         250
      Cumulative hits




                        400
                                                                                                         200
                        300
                                                                                                         150
                                                    10% increase of cyclic loads
                        200
                                                                                                         100

                        100                                                                              50
                                                                                    critical     level
                         0                                                                               0
                              0       3000          6000        9000        12000        15000       18000
                                                            Load cycles

                                                                                                                                                 14
Results and Discussion

3. Prediction of fatigue life
     Absolute energy of AE, U ∝ J(∆K), released energy due to crack growth
                                        dU/dN=B(∆K)p
                                   log(dU/dN)=plog(∆K)+log(B)                 Eq.(1)


     Paris Law: da/dN=C(∆K)m; ∆K = ?
                                    da/dN=D(dU/dN)q                           Eq.(2)


     Applies to Stage Ⅱcracking




                                                                                   15
Results and Discussion

3. Prediction of fatigue life
                                 2        crack growth rate, da/dN
                                          absolute energy rate, dU/dN
                                 1        Linear (crack growth rate, da/dN)
                                          Linear (absolute energy rate, dU/dN)
        Log(da/dN), log(dU/dN)




                                 0


                                 -1                                    log(dU/dN) = 5.7489log(∆K) - 10.865


                                 -2


                                 -3
                                                          log(da/dN) = 3.8338log(∆K) - 9.9518

                                 -4
                                   1.75     1.8         1.85         1.9         1.95       2         2.05
                                                      Stress intensity range, log(∆K)
                                                                                                             16
Results and Discussion

3. Prediction of fatigue life
                              70

                              60
                                       experimental crack
           Crack length, mm




                              50
                                       predicted crack
                              40

                              30

                              20

                              10

                              0
                                   0     10,000          20,000    30,000   40,000
                                                     Load cycles
                                                                                     17
Results and Discussion

4. AE-detected cracking locations




        crack path




                                                     18
Conclusions and Perspective
Summary:
   AE absolute energy can provide warning signs for critical cracking in
    steel bridge material.
   Absolute energy rate was found to most suitable feature.
   Specific material constants in terms of both AE and crack growth
    behavior should be evaluated.
   Robust data filtering techniques are required.
   The combination of a Swansong II filter with a waveform-based
    approach was found to be appropriate.
Further work:
   Mechanism of AE corresponding to crack growth in welded bridge
    elements
                                                                       19
Acknowledgements

   This work is performed under the support of the U.S. Department of
    Commerce,       National    Institute     of     Standards    and
    Technology, Technology Innovation Program, Cooperative
    Agreement Number 70NANB9H9007. Special thanks to Jean-Louis
    Staudenmann.


   South Carolina DOT for providing access to bridges and related
    information for this project.


   Valery Godinez, Adrian Pollock, Miguel Gonzalez (Mistras); Brian
    Metrovich (Case Western Reserve Univ.); Fabio Matta (Univ. of
    South Carolina).

                                                                     20
Thanks for your time and attention
Annex1 Construction of a and dU/dN arrays for Fatigue Life Prediction

   Array of a:
          original a: ao

              final a:
                                    o   generally, Kmax=F∙S∙(π∙afinal)1/2 = KIC ,
                                        where F=f(geometry), S- applied stress, KIC – fracture toughness
                                    o   compact tension(CT) specimen-cantilever beam:
                                               Kmax=Fp∙P/(t∙b1/2) = KIC ,
                                        where Fp =fp (av/b), av=(afinal-1+ afinal)/2, P-applied load, t-thickness, b-width
    CT             SE
                                    o   single edge(SE) specimen-freely supported beam:
                                               Kmax=F∙Sg∙(π∙afinal)1/2 = KIC,
                                         where F=f(av/b), Sg = 6M/(b2∙t), M-applied moment
              a(i+1)=r∙ai , r ≈1.10,

   Array of dU/dN:
            original dU/dN: (du/dN)o
            final dU/dN: (dU/dN)final=B(∆KIC )p , ∆K= KIC∙(1-R), where B, p-material constants, R-load ratio
            (dU/dN)(i+1) / (dU/dN)i = B(∆K(i+1) / (∆K )i ) p = B(r) p/2 , r ≈1.10
                                                                                                                             22

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Remote detection of stage ii to stage iii cracking in steel bridge girder material

  • 1. Remote Detection of Stage II to Stage III Cracking in Steel Bridge Girder Material M. Hossain ASNT 20th Annual Research Symposium & Spring Conference San Francisco, California 21-25 March, 2011 This project is sponsored by the U.S. Department of Commerce, NIST-TIP (Cooperative Agreement Number 70NANB9H9007)
  • 2. Background S Safe area N da/dN unstable cracking critical cracking level Paris Law: stable cracking da/dN=C(∆K)m threshold K 2
  • 3. Background Voltage, mV Time, μS Acoustic emission (AE) techniques:  High sensitivity and reliability  Capability of locating and quantifying active cracks 3
  • 4. Objective Bridge Prognostic System • Self-Powered • Wireless Sensor Network • Structural Bridge Health Prognosis Current tasks • Understand mechanism of acoustic emission(AE) corresponding to crack growth behavior in the steel bridge material • Data interpretation to identify structural damage and deterioration • Modeling to assess the remaining fatigue life 4
  • 5. Experimental Procedure 12.0 in 3.25 in R15I WDI 9.5 in 12.0 in AE-monitored fatigue tests: Compact tension (CT) specimens, made of A572G50 MTS 810 hydraulic machine Crack growth: clip gage, microscope and fiber light AE sensors: R15I 5, WDI 3 Sensor Highway II-Remote Asset Integrity Monitor 5
  • 6. Data Filtering and Reducing Procedures 1. Eliminate AE collected below 80% of peak load Yielding 2 4 Crack extension Pmax Y-stress Crack opening load Pmean Crack closure Grating 1 3 5 Pmin Reversed yielding time Y-strain Stress-strain behavior at crack tip in a load cycle 6
  • 7. Data Filtering and Reducing Procedures Counts 2. Friction emission tests to understand Peak Threshold characteristics of noise amplitude 3. Pencil lead break tests to understand characteristics of genuine hits Rise time Duration 2 3 7
  • 8. Data Filtering and Reducing Procedures 4. Swansong Ⅱ filter to minimize mechanical noise 8
  • 9. Data Filtering and Reducing Procedures 5. Evaluate quality of filtered AE data 9
  • 10. Results and Discussion 1. Sparse dataset 4 3.5 Hit rate 3 2.5 Hit rate 2 10% increase of cyclic loads 1.5 1 0.5 0 0 5,000 10,000 15,000 20,000 Load cycles 10
  • 11. Results and Discussion 2. Determination of critical cracking level 400,000 350 Cumulative absolute energy Maximum stress intensity, MPa√m 350,000 Cumulative absolute energy, aJ 300 Maximum stress intensity 300,000 250 250,000 200 200,000 150 150,000 10% increase of cyclic loads 100 100,000 50,000 50 critical level 0 0 0 3,000 6,000 9,000 12,000 15,000 18,000 Load cycles 11
  • 12. Results and Discussion 2. Determination of critical cracking level 16,000,000 350 Cumulative signal strength Maximum stress intensity, Mpa√m Cumulative signal strength, V-T 14,000,000 300 Maximum stress intensity 12,000,000 250 10,000,000 200 8,000,000 150 6,000,000 10% increase of cyclic loads 100 4,000,000 2,000,000 50 critical level 0 0 0 3,000 6,000 9,000 12,000 15,000 18,000 Load cycles 12
  • 13. Results and Discussion 2. Determination of critical cracking level 35,000 30,000 Cumulative counts Cumulative counts 25,000 20,000 10% increase of cyclic loads 15,000 10,000 5,000 critical level 0 0 3,000 6,000 9,000 12,000 15,000 18,000 Load cycles 13
  • 14. Results and Discussion 2. Determination of critical cracking level 600 350 Cumulative hits Maximum stress intensity, MPa√m 500 300 Maximum stress intensity 250 Cumulative hits 400 200 300 150 10% increase of cyclic loads 200 100 100 50 critical level 0 0 0 3000 6000 9000 12000 15000 18000 Load cycles 14
  • 15. Results and Discussion 3. Prediction of fatigue life  Absolute energy of AE, U ∝ J(∆K), released energy due to crack growth dU/dN=B(∆K)p log(dU/dN)=plog(∆K)+log(B) Eq.(1)  Paris Law: da/dN=C(∆K)m; ∆K = ? da/dN=D(dU/dN)q Eq.(2)  Applies to Stage Ⅱcracking 15
  • 16. Results and Discussion 3. Prediction of fatigue life 2 crack growth rate, da/dN absolute energy rate, dU/dN 1 Linear (crack growth rate, da/dN) Linear (absolute energy rate, dU/dN) Log(da/dN), log(dU/dN) 0 -1 log(dU/dN) = 5.7489log(∆K) - 10.865 -2 -3 log(da/dN) = 3.8338log(∆K) - 9.9518 -4 1.75 1.8 1.85 1.9 1.95 2 2.05 Stress intensity range, log(∆K) 16
  • 17. Results and Discussion 3. Prediction of fatigue life 70 60 experimental crack Crack length, mm 50 predicted crack 40 30 20 10 0 0 10,000 20,000 30,000 40,000 Load cycles 17
  • 18. Results and Discussion 4. AE-detected cracking locations crack path 18
  • 19. Conclusions and Perspective Summary:  AE absolute energy can provide warning signs for critical cracking in steel bridge material.  Absolute energy rate was found to most suitable feature.  Specific material constants in terms of both AE and crack growth behavior should be evaluated.  Robust data filtering techniques are required.  The combination of a Swansong II filter with a waveform-based approach was found to be appropriate. Further work:  Mechanism of AE corresponding to crack growth in welded bridge elements 19
  • 20. Acknowledgements  This work is performed under the support of the U.S. Department of Commerce, National Institute of Standards and Technology, Technology Innovation Program, Cooperative Agreement Number 70NANB9H9007. Special thanks to Jean-Louis Staudenmann.  South Carolina DOT for providing access to bridges and related information for this project.  Valery Godinez, Adrian Pollock, Miguel Gonzalez (Mistras); Brian Metrovich (Case Western Reserve Univ.); Fabio Matta (Univ. of South Carolina). 20
  • 21. Thanks for your time and attention
  • 22. Annex1 Construction of a and dU/dN arrays for Fatigue Life Prediction  Array of a:  original a: ao  final a: o generally, Kmax=F∙S∙(π∙afinal)1/2 = KIC , where F=f(geometry), S- applied stress, KIC – fracture toughness o compact tension(CT) specimen-cantilever beam: Kmax=Fp∙P/(t∙b1/2) = KIC , where Fp =fp (av/b), av=(afinal-1+ afinal)/2, P-applied load, t-thickness, b-width CT SE o single edge(SE) specimen-freely supported beam: Kmax=F∙Sg∙(π∙afinal)1/2 = KIC, where F=f(av/b), Sg = 6M/(b2∙t), M-applied moment  a(i+1)=r∙ai , r ≈1.10,  Array of dU/dN:  original dU/dN: (du/dN)o  final dU/dN: (dU/dN)final=B(∆KIC )p , ∆K= KIC∙(1-R), where B, p-material constants, R-load ratio  (dU/dN)(i+1) / (dU/dN)i = B(∆K(i+1) / (∆K )i ) p = B(r) p/2 , r ≈1.10 22

Editor's Notes

  1. In-service steel bridges are reaching their fatigue lives every year. Fatigue life is usually described as S-N curve. Here, S represents applied stress. N is the number of load cycles. For a given material and set of loading conditions, if the number of load cycles exceeds the fatigue life, crack will develop in the structure. Crack growth rate curve describes crack growth behavior. da/dN is crack growth rate. Delta K is stress intensity range. Crack growth has three stages: Stage I-low speed cracking near threshold, Stage II-stable cracking and Stage III-unstable cracking. Stage Ⅱ is of practical importance. The stage Ⅲ will result in catastrophic failure, so the critical cracking level is the transition point between stage Ⅱ and stage Ⅲ.The pictures come from an in-service and cracked steel bridge in South Carolina. There is a growing need for nondestructive testing techniques to evaluate the fatigue damage and predict remaining fatigue life.
  2. Joint venture project. Imagine:if no accurate data interpretation, the acquired signals are useless no matter how excellent the techniques, the instruments are.Importance of current task
  3. Joint venture project. Imagine:if no accurate data interpretation, the acquired signals are useless no matter how excellent the techniques, the instruments are.Importance of current task
  4. It has been demonstrated that AE technique is able to detect cracking location, identify structural damage and predict fatigue life for steel bridge material.Perspective: Mechanism of AE corresponding to crack growing under varied loading conditions and in welded bridge elements
  5. PAC: equipment setup and data acquisition