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5, Testing

The document discusses the need for testing structures and materials to validate models, ensure safety and reliability, and identify failure modes. It covers different levels of testing from coupons to full scale and different techniques including digital image correlation and thermoelastic stress analysis that can be used. Low-cost systems for condition monitoring are presented along with examples of applications.

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14 views31 pages

5, Testing

The document discusses the need for testing structures and materials to validate models, ensure safety and reliability, and identify failure modes. It covers different levels of testing from coupons to full scale and different techniques including digital image correlation and thermoelastic stress analysis that can be used. Low-cost systems for condition monitoring are presented along with examples of applications.

Uploaded by

dhairyaapandya
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF, TXT or read online on Scribd
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ENGG409 Structural Integrity

Testing

Dr Will Christian
w.j.r.christian@liverpool.ac.uk
Harrison Hughes, Room 110
This week

• Need for testing


• Validation
• Full scale testing
• Inspection activity
Motivation for Week
• Students often don’t realise how important it is to test materials, structures and
systems

• In previous years as part of an assignment I asked students to:

Describe a test capable of determining Paris law constants for a material


Using what material
properties
 Create a finite element model of the specimen
 Use computational fluid dynamics Look at the name
of that technique
✓ Cyclically load cracked specimen and monitor with a camera

3
Necessity of Testing

• Material properties must be known before


modelling anything

• New manufacturing processes need to be


assessed before implementing them on the
production line

• Safety and reliability need to be


demonstrated for regulators

5
Testing Pyramid

Too expensive to test

6 Image Source: Airbus


Coupon Testing
• Models need a lot of material
properties

Typical metal:
𝐸, 𝐺, 𝜈
𝜎𝑌𝑆 , 𝜎𝑈𝑆
Failure
stresses
Typical composite:
𝐸11 , 𝐸22 , 𝐺12 , 𝐺23 , 𝜈12 , 𝜈23
𝐹1𝐶 , 𝐹1𝑇 , 𝐹2𝐶 , 𝐹2𝑇 , 𝐹12 , ⋯

7
Full Scale Testing
Multiple actuators
allow for multiple
load cases
Boundary
condition

Hydraulic jacks to
apply loads

Simplification
(Jet engine
removed)

8
Validation

• If failure puts lives at risk then computer


models need validation

• Computer models are created for every


conceivable load case

• Select load cases are experimentally tested

• Experimental and model results are


compared

9
Other Reasons for Testing

• Identify failure modes well before they occur in


service

• Develop and demonstrate capability of NDE


techniques to locate defects

• Determine most effective way to repair


structures and confirm safety of repair methods

10 Image Source: Aussie DSTO


Testing Coupons

• Study failure behaviour


• Test different materials and geometries
• Simulate loading conditions
• Develop non destructive testing (NDT)
techniques
Thermoelastic Stress Analysis (TSA)

• Determine surface stresses


• Non contact
• Accurate and quick analysis
Digital Image Correlation DIC

• Non contact
• Determine surface strains
• Large areas can be monitored
DIMES system
FLIR Lepton 3.5 8MP Sony IMX219
Microbolometer Visual camera
£200 £20

350Ω RSG quarter bridge Raspberry Pi 4B 4GB


configuration with ADC £54
£20

Dimensions: H 55mm x W 92mm x D 95mm


Additional items Inc. case, SD card, ring light
Mass: 290g
£40
Total cost: £334
DIMES system

Pre-cracked Crack propagation


TSA from low-cost sensor
16:30 19:00 19:30

20:00 20:45 21:30


Damage in structures
Visual image TSA overlay
DIC from low-cost sensor
16:30 19:00 19:30

20:00 20:45 21:30


Condition monitoring
9.5 hours

8.25 hours
Feature Vector Difference

0.25 hours 4.5 hours


Full Scale testing

• Monitor structures under load


• Use results to improve design
• Test and find limits
• Provide structural readiness
DIMES in the LOV wing
DIMES on LOV wing
Installed System

Field of View

Approx Lepton FOV


Cockpit fatigue loading
• Cockpit fatigue test at Airbus
• Cockpit is pressurised over 110 seconds to <700mbar and then de-pressurised over 5 seconds
DIMES installation
Installation Camera FOV
FEA and DIC
Before repair After repair

Load ≈ 400mb Load ≈ 400mb


Inspections
• Holes create stress concentrations
• Aircraft have a lot of holes
• How can manufacturers improve
structural integrity?
Cold Expansion
Cold Expanding holes

Source: https://www.youtube.com/watch?v=_yOTga_3eTM
Cold Expanded hole Activity
CE UX
Crack trajectory Crack trajectory

• Observe both specimens and their


Fracture surface Fracture surface
fractured surfaces
• Why do you think cold expansion
is used?
Discussion

• Why use cold expanding?


• Is it possible to have too much of a good thing….?
Recap

• Considered how and why


structures are tested

• Next week:
• Guest lecture from Lloyd
Fletcher of UKAEA

31

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