Structural Health and Condition Monitoring with Acoustic Emission and Guided Ultrasonic Waves: What about Long-Term Durability of Sensors, Sensor Coupling and Measurement Chain?
Source abstract
Abstract
Acoustic Emission (AE) and Guided Ultrasonic Waves (GUWs) are non-destructive testing (NDT) methods in several industrial sectors for, e.g., proof testing and periodic inspection of pressure vessels, storage tanks, pipes or pipelines and leak or corrosion detection. In materials research, AE and GUW are useful for characterizing damage accumulation and microscopic damage mechanisms. AE and GUW also show potential for long-term Structural Health and Condition Monitoring (SHM and CM). With increasing computational power, even online monitoring of industrial manufacturing processes has become feasible. Combined with Artificial Intelligence (AI) for analysis this may soon allow for efficient, automated online process control. AI also plays a role in predictive maintenance and cost optimization. Long-term SHM, CM and process control require sensor integration together with data acquisition equipment and possibly data analysis. This raises the question of the long-term durability of all components of the measurement system. So far, only scant quantitative data are available. This paper presents and discusses selected aspects of the long-term durability of sensor behavior, sensor coupling and measurement hardware and software. The aim is to identify research and development needs for reliable, cost-effective, long-term SHM and CM with AE and GUW under combined mechanical and environmental service loads.
Source: crossref · Quality: baseline
Research context
OpenAlex topics: Ultrasonics and Acoustic Wave Propagation · Advanced machining processes and optimization · Fault Detection and Control Systems
SciVX discovery tags are terminology-based. OpenAlex topics are source-provided classifications.
Affiliations
Empa, Swiss Federal Laboratories for Materials Science and Technology, CH-8600 Dübendorf, Switzerland
References (100+)
Show source-provided references
1. An Experiment on the Progression of Fracture (A Preliminary Report)
2. Akustische Untersuchung der Bildung von Martensitnadeln
3. On the problem of the propagation of ultrasonic oscillations in various bodies
4. Miller, R.K., Hill, E.v.K., and Moore, P.O. (2005). Nondestructive Testing Handbook Volume 6, Acoustic Emission Testing (AE), American Society for Nondestructive Testing (ASNT). [3rd ed.].
5. Workman, G.L., Kishoni, D., and Moore, P.O. (2007). Nondestructive Testing Handbook Volume 7, Ultrasonic Testing (UT), American Society for Nondestructive Testing (ASNT). [3rd ed.].
6. A review on ultrasonic guided wave technology10.1080/14484846.2017.1373385 ↗
7. Acoustic Emission, Principles and Instrumentation
8. Progress in Detecting Transverse Matrix Cracking using Modal Acoustic Emission
9. Le Gall, T., Monnier, T., Fusco, C., Godin, N., and Hebaz, S.E. (2018). Towards Quantitative Acoustic Emission by Finite Element Modelling: Contribution of Modal Analysis and Identification of Pertinent Descriptors. Appl. Sci., 8.10.3390/app8122557 ↗
10. Simulation of Acoustic Emission in Planar Carbon Fiber Reinforced Plastic Specimens10.1007/s10921-010-0071-7 ↗
11. Finite Element Modelling of Cracks as Acoustic Emission Sources10.1007/s10921-015-0278-8 ↗
12. Damage Evolution in Wood—Synchrotron based microtomography (SRμCT) as complementary evidence for interpreting acoustic emission behavior10.1515/hf-2014-0152 ↗
13. Correlation between acoustic emission signals and delaminations in carbon fiber-reinforced polymer-matrix composites: A new look at mode I fracture test data
14. Industry 4.0: A survey on technologies, applications and open research issues
15. A Review of Artificial Intelligence Methods for Condition Monitoring and Fault Diagnosis of Rolling Element Bearings for Induction Motor
16. Artificial intelligence within the interplay between natural and artificial computation: Advances in data science, trends and applications10.1016/j.neucom.2020.05.078 ↗
17. Modelling and monitoring of abrasive finishing processes using artificial intelligence techniques: A review10.1016/j.jmapro.2020.06.013 ↗
18. A review on big data real-time stream processing and its scheduling techniques10.1080/17445760.2019.1585848 ↗
19. Mapping the Big Data Landscape: Technologies, Platforms and Paradigms for Real-Time Analytics of Data Streams10.1109/ACCESS.2020.3046132 ↗
20. Prager, M., and Tilley, R. (1996). Acoustic emission monitoring for inspection of seam-welded hot reheat piping in fossil power plants. Nondestructive Evaluation of Utilities and Pipelines, Proceedings of the SPIE 2947, Nondestructive Evaluation Techniques for Aging Infrastructure and Manufacturing, Scottsdale, AZ, USA, 3–5 December 1996, SPIE.
21. Inspection of power plant headers utilizing acoustic emission monitoring10.1016/S0963-8695(98)00068-1 ↗
22. A survey of the state of condition-based maintenance (CBM) in the nuclear power industry10.1016/j.anucene.2017.10.010 ↗
23. Chemical-Industry Applications of Acoustic Emission
24. The uses of passive measurement of acoustic emissions from chemical engineering processes10.1016/S0009-2509(00)00540-6 ↗
25. Evaluation of the residual service life of chemical technological equipment at the Odessa port plant10.1007/s11003-011-9324-6 ↗
26. Bernardo, J.T. (2015, January 6–9). Cognitive and Functional Frameworks for Hard/Soft Fusion for the Condition Monitoring of Aircraft. Proceedings of the 18th International Conference on Information Fusion, Washington, DC, USA.
27. Kralovec, C., and Schagerl, M. (2020). Review of Structural Health Monitoring Methods Regarding a Multi-Sensor Approach for Damage Assessment of Metal and Composite Structures. Sensors, 20.10.3390/s20030826 ↗
28. Margot, R.D.Y. (2005). Strategische Signalerfassung mit piezoelektrischen Sensoren für die Prozessüberwachung in der Zerspanung. [Ph.D. Thesis, ETHZ]. (In German).
29. Deep Learning for In Situ and Real-Time Quality Monitoring in Additive Manufacturing Using Acoustic Emission10.1109/TII.2019.2910524 ↗
30. Piezo acoustic versus opto-acoustic sensors in laser processing
31. (2021, November 14). EN 12819. LPG Equipment and Accessories—Inspection and Requalification of LPG Tanks Greater Than 13 m3. Available online: https://standards.iteh.ai/catalog/standards/cen/ba842fdb-4284-4b0b-810a-0f90b87a767c/en-12819-2019.
32. (2018). ASTM D1067/D1067-M. Standard Practice for Acoustic Emission Examination of Fiberglass Reinforced Plastic Resin (FRP) Tanks/Vessels. Am. Soc. Test. Mater. Int.
33. Jiao, P.C., Egbe, K.-J.I., Xie, Y.W., Matin Nazar, A., and Alavi, A.H. (2020). Piezoelectric Sensing Techniques in Structural Health Monitoring: A State-of-the-Art Review. Sensors, 20.10.3390/s20133730 ↗
34. Uchino, K. (2017). The Development of Piezoelectric Materials and the New Perspective. Advanced Piezoelectric Materials, Elsevier Woodhead Publishing. [2nd ed.].10.1016/B978-0-08-102135-4.00001-1 ↗
35. Piezoelectric materials for sustainable building structures: Fundamentals and applications10.1016/j.rser.2018.09.038 ↗
36. High-Temperature Piezoelectric Crystals for Acoustic Wave Sensor Applications10.1109/TUFFC.2016.2527599 ↗
37. Tittmann, B., Batista, C.F.G., Trivedi, Y.P., Lissenden III, C.J., and Reinhardt, B.T. (2019). State-of-the-Art and Practical Guide to Ultrasonic Transducers for Harsh Environments Including Temperatures above 2120 °F (1000 °C) and Neutron Flux above 1013 n/cm2. Sensors, 19.10.3390/s19214755 ↗
38. Requirements for the transfer of lead-free piezoceramics into application10.1016/j.jmat.2018.02.001 ↗
39. Structural health monitoring of polymer-matrix composite using embedded piezoelectric ceramic transducers during several four-points bending tests10.1088/1361-665X/abbc59 ↗
40. Lin, B., and Giurgiutiu, V. (2005, January 7–10). Review of in situ fabrication methods of piezoelectric wafer active sensor for sensing and actuation applications. Proceedings of the SPIE 5765, Smart Structures and Materials 2005: Sensors and Smart Structures Technologies for Civil, Mechanical, and Aerospace Systems, SPIE Smart Structures and Materials + Nondestructive Evaluation and Health Monitoring, San Diego, CA, USA.10.1117/12.597779 ↗
41. Bachmann, F. (2013). Integration of Monolithic Piezoelectric Damping Devices into Adaptive Composite Structures. [Ph.D. Thesis, ETHZ]. No. 20747.
42. Piezoelectric fiber composite with interdigitated electrodes10.1177/1045389X9700801101 ↗
43. Active fiber composites for the generation of Lamb waves10.1016/j.ultras.2008.05.003 ↗
44. Structural health monitoring for delamination detection and location in wind turbine blades employing guided waves10.1002/we.2316 ↗
45. Di Rito, G.P., Chiarelli, M.R., and Luciano, B. (2020). Dynamic Modelling and Experimental Characterization of a Self-Powered Structural Health-Monitoring System with MFC Piezoelectric Patches. Sensors, 20.10.3390/s20040950 ↗
46. Piezoelectric thin films: An integrated review of transducers and energy harvesting10.1088/0964-1726/25/5/053002 ↗
47. Piezoelectric materials for high frequency medical imaging applications: A review10.1007/s10832-007-9044-3 ↗
48. Integration of piezoelectric transducers (PZT and PVDF) within polymer-matrix composites for structural health monitoring applications: New success and challenges10.1080/19475411.2020.1830196 ↗
49. Gyekenysei, A., Shepard, S.M., Huston, D.R., Emin Aktan, A., and Shull, P.J. (2002, January 17–21). Guided wave ultrasonics for NDE of aging aircraft components. Proceedings of the SPIE 4704, Nondestructive Evaluation and Health Monitoring of Aerospace Materials and Civil Infrastructures, San Diego, CA, USA.
50. Application of air-coupled ultrasonics for the characterization of polymer and polymer-matrix composite samples10.1016/j.polymertesting.2016.11.002 ↗
51. Review of the use of air-coupled ultrasonic technologies for nondestructive testing of wood and wood products10.1016/j.compag.2017.03.015 ↗
52. Review of piezoelectric micromachined ultrasonic transducers and their applications10.1088/1361-6439/aa851b ↗
53. Ozevin, D. (2020). MEMS Acoustic Emission Sensors. Appl. Sci., 10.10.3390/app10248966 ↗
54. Breckinridge, J., and Wang, Y.T. (2005, January 21–26). A review of the fabrication of optic fiber. Proceedings of the Optical Design and Fabrication (ICO20). ICO20:Optical Devices and Instruments, Changchun, China.
55. A review of recent developed and applications of plastic fiber optic displacement sensors10.1016/j.measurement.2013.11.007 ↗
56. Talataisong, W., Ismaeel, R., Beresna, M., and Brambilla, G. (2019). Suspended-Core Microstructured Polymer Optical Fibers and Potential Applications in Sensing. Sensors, 19.10.3390/s19163449 ↗
57. Textile-integrated polymer optical fibers for healthcare and medical applications10.1088/2057-1976/abbf5f ↗
58. Development of Fiber Optic Acoustic Emission Sensors for Applications in Civil Infrastructures10.1260/1369-4332.15.8.1471 ↗
59. Willberry, J.O., Papaelias, M., and Franklyn Fernando, G. (2020). Structural Health Monitoring Using Fibre Optic Acoustic Emission Sensors. Sensors, 20.10.3390/s20216369 ↗
60. Micro-/Nanofiber Optics: Merging Photonics and Material Science on Nanoscale for Advanced Sensing Technology10.1016/j.isci.2019.100810 ↗
61. Multifunctional integration on optical fiber tips: Challenges and opportunities10.1117/1.AP.2.6.064001 ↗
62. Fiber-optic ultrasonic sensors and applications10.7498/aps.66.074205 ↗
63. A Review of Laser Doppler Vibrometry for Structural Health Monitoring Applications10.4028/www.scientific.net/KEM.518.1 ↗
64. Laser-based linear and nonlinear guided elastic waves at surfaces (2D) and wedges (1D)10.1016/j.ultras.2013.05.013 ↗
65. Güemes, A., Fernandez-Lopez, A., Pozo, A.R., and Sierra-Pérez, J. (2020). Structural Health Monitoring for Advanced Composite Structures: A Review. J. Compos. Sci., 4.10.3390/jcs4010013 ↗
66. Giurgiutiu, V. (2022). Stress, Vibration, and Wave Analysis in Aerospace Composites—SHM and NDE Applications, Elsevier Academic Press. [1st ed].10.1016/B978-0-12-813308-8.00005-3 ↗
67. Zelenyak, A.M., Hamstad, M., and Sause, M.G.R. (2014, January 3–5). Finite Element Modeling of Acoustic Emission Signal Propagation with Various Shaped Waveguides. Proceedings of the 31st Conference of the European Working Group on Acoustic Emission (EWGAE), Dresden, Germany. Paper We.1.A.4.
68. Acoustic Emission Monitoring of Leaks in Pipes for Transport of Liquid and Gaseous Media: A Model Experiment10.4028/www.scientific.net/AMR.13-14.351 ↗
69. Acoustic Emission Leak Testing of Pipes for Pressurized Gas Using Active Fiber Composite Elements as Sensors
70. Universal Waveguide for the Acoustic-Emission Evaluation of High-Temperature Industrial Objects10.1134/S1061830918030099 ↗
71. Experimental Estimation of the Waveguide Effect on the Acoustic Emission Signal Parameters in Monitoring Facilities with a Long Surface Radius of Curvature10.3103/S1052618820110059 ↗
72. Detection of Acoustic Emission (AE) from Zinc Embrittlement Cracking During Welding Using Optical Fiber AE Monitoring System10.1007/s10921-012-0136-x ↗
73. (2021, November 14). Vallen Systeme GmbH, ATEX Products. Available online: https://www.vallen.de/products/atex-products/.
74. Physical Acoustics Corporation (2021, November 14). Intrinsically Safe Sensors. Available online: https://www.physicalacoustics.com/intrinsically-safe-sensors/.
75. (2017). ASTM E650/E650-M. Standard Guide for Mounting Piezoelectric Acoustic Emission Sensors. Am. Soc. Test. Mater. Int.
76. An Overview of Different Possibilities to Master the Challenge of Coupling an AE-Sensor to an Object of Interest Partly Using Examples of Previous Investigations
77. Study on the Effect of Coupling Materials on the Ultrasonic Signals Detection of Partial Discharge10.1088/1755-1315/440/3/032120 ↗
78. A Review on the Applications of Acoustic Emission Technique in the Study of Stress Corrosion Cracking10.3390/cmd2010001 ↗
79. Listening to Radiation Damage In Situ: Passive and Active Acoustic Techniques10.1007/s11837-019-03898-7 ↗
80. A custom acoustic emission monitoring system for harsh environments: Application to freezing-induced damage in alpine rock walls10.5194/gi-1-155-2012 ↗
81. Measuring and localizing acoustic emission events in snow prior to fracture10.1016/j.coldregions.2014.12.002 ↗
82. Picosecond laser surface treatment and analysis of thermoplastic composites for structural adhesive bonding10.1016/j.compositesb.2020.107939 ↗
83. (2017). ASTM E751. Standard Practice for Acoustic Emission Monitoring During Resistance Spot-Welding. Am. Soc. Test. Mater. Int.
84. Felux, M.W. (2016). Acoustic Emission Monitoring on Bridges under Regular Operating Conditions. [Ph.D. Thesis, ETHZ]. No. 23502.
85. An improved piezoelectric acoustic emission transducer10.1121/1.387763 ↗
86. Development of seismology-based acoustic emission methods for civil infrastructure applications10.1063/1.4789201 ↗
87. Tan, A.C.C., Kaphle, M.R., and Thambiratnam, D. (2009, January 20–24). Structural health monitoring of bridges using acoustic emission technology. Proceedings of the 8th International Conference on Reliability, Maintainability and Safety (ICRMS 2009), Chengdu, China.10.1109/ICRMS.2009.5269952 ↗
88. Acoustic emission monitoring of bridges: Review and case studies10.1016/j.engstruct.2010.02.020 ↗
89. Laboratory and field studies on the use of acoustic emission for masonry bridges10.1016/j.ndteint.2013.01.006 ↗
90. On-Site Acoustic-Emission Monitoring for a Prestressed Concrete BT-54 AASHTO Girder Bridge10.1061/(ASCE)CF.1943-5509.0001440 ↗
91. Simple discrimination method between False Acoustic Emission and Acoustic Emission revealed by piezoelectric sensors, in Gran Sasso mountain measurements (L)10.1121/1.1756895 ↗
92. Tomizuka, M. (2011, January 7–10). Modal analysis of Dongying Yellow River Bridge for long term monitoring. Proceedings of the Sensors and Smart Structures Technologies for Civil, Mechanical, and Aerospace Systems, San Diego, CA, USA.
93. Tillman, A.S., Schultz, A.E., and Campos, J.E. (2015). Protocols and Criteria for Acoustic Emission Monitoring of Fracture-Critica l Steel Bridges, Minnesota Department of Transportation. Report MN/RC 2015-36.
94. Bayane, I., and Brühwiler, E. (2019, January 27–29). Acoustic emission and ultrasonic testing for fatigue damage detection in a RC bridge deck slab. Proceedings of the Fifth Conference on Smart Monitoring, Assessment and Rehabilitation of Civil Structures SMAR2019, Potsdam, Germany.
95. Bayane, I. (2021). Fatigue Examination of Reinforced-Concrete Bridge Slabs Using Acoustic Emission and Strain Monitoring Data. [Ph.D. Thesis, EPFL]. No. 8587.
96. Long-term acoustic monitoring at North Sea well site 22/4b10.1016/j.marpetgeo.2015.02.011 ↗
97. Brunner, A.J. (2011, January 19–21). From materials and components to structural health monitoring systems and smart structures: Examples from research on advanced composites. Proceedings of the International Conference on Advanced Technology in Experimental Mechanics, atem’11, Kobe, Japan.
98. Anderegg, P., Broennimann, R., and Meier, U. (2019, January 27–29). Long-Term-Monitoring of CFRP-cables over almost a quarter of a century. Proceedings of the Fifth Conference on Smart Monitoring, Assessment and Rehabilitation of Civil Structures SMAR2019, Potsdam, Germany.
99. Brunner, A.J., Birchmeier, M., Melnykowycz, M., and Barbezat, M. (2007, January 16–18). Piezoelectric Active Fiber Composites as Sensor Elements for Structural Health Monitoring and Adaptive Material Systems. Proceedings of the 6th International Symposium on Advanced Composite Technologies (COMP-07), Corfu, Greece. Paper No.037.
100. An experimental and theoretical fatigue study on macro fiber composite (MFC) under thermo-mechanical loadings10.1016/j.euromechsol.2017.06.005 ↗