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1209

Acoustic Emis
30. Acoustic Emission

Kanji Ono

30.3 Source Location ................................... 1215


Acoustic emission (AE) originates from mechanical
deformation and fracture, as well as from phase 30.4 Sources of Emissions
transformation, corrosion, friction, and magnetic and Materials Behavior ........................ 1216
processes. It refers to the generation of transient 30.4.1 Plastic Deformation of Metals ..... 1217
elastic waves due to the rapid release of energy 30.4.2 Fracture and Crack Growth ......... 1218
from a localized source or sources within a mater- 30.4.3 Fiber Fracture and Delamination
ial or structure. It is an indispensable and effective of Composite Materials............... 1221
nondestructive inspection method and a valuable 30.4.4 Rock and Concrete Fracture ........ 1222
tool of materials research, detecting dynamic mi- 30.4.5 Other Emission Sources .............. 1223
croscopic processes of materials. Sensors attached
30.5 Structural Integrity Monitoring ............. 1224
to the structure detect AE signals, from which the 30.5.1 Fiber-Reinforced Composite
locations and activity levels of the sources are Pressure Vessels, Tanks,
evaluated, and structural integrity is assessed. and Piping ............................... 1224
30.5.2 Metal Pressure Vessels, Tanks,
30.1 Background ........................................ 1209 and Piping ............................... 1225
30.5.3 Aerospace ................................ 1225
30.2 Acoustic Emission Signals ..................... 1210 30.5.4 Geological Structures ................. 1226
30.2.1 AE Signals and Source Functions.. 1210 30.5.5 Bridges .................................... 1226
30.2.2 Sensors .................................... 1213
30.2.3 Signal Characterization .............. 1215 References .................................................. 1227

Acoustic emission (AE) is transient elastic waves pro- yielding regions in alloys and at delamination, and
duced by the rapid release of strain energy from fiber and matrix cracks in fiber-reinforced compos-
a localized source or sources within a material or ites. Other active sources of AE include fretting at
structure [30.1–7]. This term (or microseismic activ- extant flaws, especially in concrete structures, leaks
ity in the geotechnical field) is also used to describe of pressurized fluids, and hydrogen gas evolution in
the class of phenomena that generate such waves per aqueous corrosion. All these AE phenomena provide
ASTM (American Society for Testing and Materials) the foundation of sensitive, nondestructive evaluation

Part H 30
E610-98A. Under loading, AE typically originates at methods and an effective tool in structural health moni-
cracks in structures of all kind, defective welds and toring [30.8].

30.1 Background
A dynamic mechanical event typically produces AE. terials and structures. AE is also reported in bones and
When a crack advances under stress, it proceeds in teeth [30.11] and its use for biomedical studies has ex-
discrete steps that give rise to AE from the stress re- panded to knee and hip joints [30.12, 13] and to soft
laxation at the crack tip [30.9, 10]. AE can originate tissues and ligaments [30.14–16]. Mechanical deforma-
from a number of mechanisms in any engineering ma- tion and fracture are the primary sources of AE, while
1210 Part H Engineering Acoustics

phase transformation, corrosion, friction, and magnetic or periodic inspection. AE can continuously monitor
processes, among others, also produce AE [30.17, 18]. the integrity of a structure in service. AE is a passive
The elastic waves then travel through the structure to test method, in that no direct excitation is applied, un-
a sensor. Wave propagation and attenuation greatly af- like the ultrasonic test method. However, AE testing
fect the nature of AE signals at the sensor. For example, does require the application of a certain stimulus to
when a section size is comparable to the wavelength, the a test piece. With bridges, live traffic and loaded trucks
wave travels as a guided wave. In thick-walled struc- are sufficient. In pressure vessels and piping, hydro-
tures, the surface wave is often the dominant mode of static pressurization slightly above the operating level
propagation, while fluids in tanks and pipes carry waves is usually employed to activate AE sources. Acoustic
efficiently over long distances [30.1]. Wave attenuation emission has become the inspection method of choice
poses serious problems to AE detection in polymeric for fiber-reinforced composite vessels and for metallic
materials and biological tissues [30.19]. Weak electri- tanks, especially in the aerospace, petrochemical, and
cal signals produced by the sensor are amplified and transport industries [30.1, 3–6, 20].
characterized, relying on the waveform shape, inten- Materials research is another area where AE is valu-
sity, frequency spectrum, and other features. For a large able because of its sensitivity to dynamic microscopic
structure, like a bridge, hundreds of sensors are used to processes [30.17,18]. It is difficult, however, to establish
cover all the critical sections under scrutiny [30.1, 20]. a mechanical phenomenon at the source of a detected
The detected AE signals are used to determine the AE signal. This stems from the high sensitivity of AE
locations and activity levels of the sources in real time. techniques (since no other means exist to independently
Results are utilized for the evaluation of the struc- observe most dynamic source phenomena). Increas-
ture or component. Since AE signals can usually travel ingly detailed modeling offers new insights in gaining
over a long distance, the entire structure can be exam- the understanding of AE mechanisms and AE signal
ined in a single test sequence, e.g., during preservice propagation [30.21–24].

30.2 Acoustic Emission Signals


We classify AE signals into two types, burst-type fiber fracture and delamination. A representative ex-
(pulse-like) and continuous-type (random noise-like) ample from a cross-ply composite test is shown in
signals. Burst-type emissions arise from distinct events Fig. 30.1, in which commonly used signal features are
of elastic energy release, such as crack advances, indicated [30.25]. It has a sharp rise, followed by an ex-
ponential decay. This ringing pattern arises from various
resonances in a structure and the resonance of the sen-
Amplitude (mV)
4 sor. Continuous-type emissions are produced by many
Rise overlapping events and observed from the plastic de-
Peak formation of metals and from liquid or gas leaks. For
2
Duration typical structural monitoring, ultrasonic frequencies of
30 kHz to 2 MHz are detected. Air-borne noise inter-
0 feres with AE measurements at lower frequencies, while
Part H 30.2

signal attenuation makes the higher frequency range dif-


–2 ficult to use. In industrial composite testing, the upper
frequency limit is 300 kHz [30.26, 27]. For applications
–4 involving concrete and rocks, a range of several kHz
0 164 328 to 100 kHz is used. For geotechnical monitoring and
Time (µs) soft tissue diagnosis, useful signal frequencies lie below
Fig. 30.1 A representative burst acoustic emission signal several kHz [30.2, 19].
waveform of the transverse matrix crack from a cross-
ply carbon fiber composite test. Defined in the figure are 30.2.1 AE Signals and Source Functions
rise time (23 μs), signal duration (205 μs), peak amplitude
(2.9 mV), along with the threshold value used (0.3 mV), An AE signal contains the information on its source,
and PAC WD wideband sensor (after [30.25]) the propagation medium (sample or structure), AE
Acoustic Emission 30.2 Acoustic Emission Signals 1211

sensor, and electrical instrument used. These can be ex- this approach is limited and impractical for most ap-
pressed by the characteristic or transfer functions of plications. AE signals detected with a wideband sensor
the source, propagation medium, sensor, and electron- can still be classified according to the generating source
ics (Hs , Hm , Ht , and He ), respectively [30.17,18]. In the types by means of pattern recognition analysis. This
time domain, the source function of a crack is force or scheme depends on the differences in the excitation of
displacement versus time history, describing the normal various modes of resonance and wave propagation and
displacement of the crack of area A. This is combined on their time history.
using a convolution integral with the impulse response AE waveforms can be simulated using elastody-
of the mechanical system (or Green’s function) to rep- namic formulation or finite element analysis for certain
resent a source. In the frequency domain, the transfer geometries [30.9, 10, 21, 22]. By varying source pa-
function of the AE signal, HAE , is given by the product rameters (rise time and source strength or the product
of the four transfer functions above, of displacement amplitude and source area), a simu-
lated waveform can be matched to the observed one
HAE = Hs Hm Ht He . (30.1) for specific test geometry. Elastodynamic displacement
solutions assuming smooth-rising source functions of
Figure 30.2 shows an example from a model signal in varying rise time are given in terms of dislocation mo-
a fiber composite [30.23]. While the AE source is given tion, or by using a moment tensor, which is commonly
as a smoothly decreasing function with frequency, the used in geophysics [30.3–5, 9, 10, 31]. Such model-
medium has the major effect on the final signal de- ing is most useful for obtaining details of a source
tected. In this example system, even a large change in by seeking the best fit of calculated and observed
Hs is hardly detectable. For a simple geometry, source waveforms. This forward-processing scheme avoids the
functions can be recovered by deconvolution when deconvolution procedure, which is prone to instability
wideband sensors are employed and the first motions in the presence of noise. This method has been used
of signals are clearly recorded [30.28–30]. However, successfully in analyzing various AE signal types in

Norm. FFT-magnitude Norm. FFT-magnitude Norm. FFT-magnitude


1 1 1
0.9
0.8 Source Material and Sensor
0.7 geometry 0.1
0.1
0.6

0.5 0.01
0.01
0.4
0.001

0 400 800 1200 1600 2000 0 400 800 1200 1600 2000 0 400 800 1200 1600 2000
Frequency (kHz) Frequency (kHz) Frequency (kHz)

Norm. FFT-magnitude Norm. FFT-magnitude

Part H 30.2
1 1

Amplifier Recorded acoustic


0.1
0.1
emission signal

0.01

0.01
0.001

0.001
0 400 800 1200 1600 2000 0 400 800 1200 1600 2000
Frequency (kHz) Frequency (kHz)
Fig. 30.2 Normalized magnitude of fast Fourier transform (FFT) of various transfer functions in the frequency domain
in log-linear plots (0–2 MHz) (after [30.23])
1212 Part H Engineering Acoustics

Displacement (× 10–12 m) Displacement (× 10–12 m) Displacement (× 10–12 m)


3 2
No. 1 S 4 No. 2 No. 3
2
1 0
2 S
0 SP
P –2
–1 0
–2 P SP –4
–2
–3
0 5 10 15 20 0 5 10 15 20 0 5 10 15 20
Time (µs) Time (µs) Time (µs)
Source location (–0.52, –4.07, –0.86) Source location (–10.63, –0.24, –0.5) Source location (–19.7, –5.31, –3.1)
Propagation distance 7.2 mm Propagation distance 12 mm Propagation distance 12 mm
ΔTpr = 0.85 µs ΔUp = 1 × 10–12 m ΔTpr = 0.35 µs ΔUp = 1 .9 × 10–12 m ΔTpr = 0.55 µs ΔUp = 3.79 × 10–12 m

Displacement (× 10–12 m) Displacement (× 10–12 m) Displacement (× 10–12 m)


3 2
S
2 Mode II 4 Mode I S Point of dilation
SP 0
1 2
0
P –2
–1 0
–2 P –4
–2 SP
–3
0 5 10 15 20 0 5 10 15 20 0 5 10 15 20
Time (µs) Time (µs) Time (µs)
ΔTpr = 0.8 µs ΔUp = 1 .22 × 10–16 m ΔTpr = 0.2 µs ΔUp = 1 .4 × 10–16 m ΔTpr = 1.1 µs ΔUp = 8.6 × 10–16 m

Fig. 30.3 Observed and matched calculated waveforms with source parameters. Unidirectional glass fiber composite test
(after [30.32])

composite materials under loading [30.32]. For exam- function, crack velocity estimates were also obtained
ple, Fig. 30.3 shows three types of failure, displacement (Fig. 30.4) [30.32].
signals observed, and matched simulated waveforms for The use of the moment-tensor representation of
a unidirectional glass-fiber composite. This led to signal a source function leads to moment tensor analysis or
classification as a function of loading. From the source moment tensor inversion [30.3–5]. This method is an
extension of a similar method used in geophysics, but
in AE applications it is important to find tensile cracks
Crack volume (×10–16 m3 ) b1 (µm)
6 in addition to shear cracks, which are the focus in seis-
7 mology. It relies on the first arriving P-waves at multiple
22 m/s
5 6.5 m/s sensor locations and obtains the tensile and shear com-
2.3 m/s 6 ponents of the source motion. This approach is most
Part H 30.2

suited for large civil engineering structures. In concrete


4 5
and rock testing, the source types of AE during crack
4 propagation have been identified (Fig. 30.5) [30.33]. In
3
most other materials testing, however, sample sizes are
3 too small to use this method.
2 The use of 3-D finite element analysis (FEA) is
2 effective in characterizing AE signals and their propaga-
1
1
Fig. 30.4 Crack volume versus source rise time, giving the
0 0 average crack velocity of 6.5 m s−1 . Data points are within
0 0.2 0.4 0.6 0.8 the zone between crack velocities of 2.3 and 22 m s−1 (af-
Source rise time (µs)
ter [30.32]) 
Acoustic Emission 30.2 Acoustic Emission Signals 1213

Frequency (kHz)
2000
0

1600 0.67×10–5

1.34 ×10–5
1200
2.01 ×10–5
800
2.68 ×10–5
S0
400 A0 3.35 ×10–5

0
Amplitude (fm)
0.4
0.2
0
Fig. 30.5 Results of moment tensor analysis of acoustic- –0.2
emission signals from simulated corrosion cracks in a large –0.4
concrete block. Arrows indicate stress direction and disks 0 0.01 0.02 0.03 0.04 0.05
Time (ms)
mark the plane of crack. Pink: tensile; blue: mixed mode;
yellow: shear crack (after [30.33]) Fig. 30.6a,b Simulated Lamb wave from a finite crack at
the mid-plane in a carbon-fiber composite plate, propagated
tion. A wide range of AE signals generated and propa- 50 mm. (a) Choi–Williams distribution diagram, showing dominant
gated on a plate, both isotropic metals and anisotropic S0 mode (zeroth order symmetric Lamb mode). (b) waveform of
composites, are analyzed [30.21–24]. The completed displacement, normal to the plate [30.24]
modeling includes Lamb waves generated by an artifi-
cial source in thin and thick plates, the effects of the of a few tens of kV s/m−1 , these are 20–40 dB more
source rise time, monopole versus dipole sources, plate sensitive than those used for conventional ultrasonic
thickness, and plate width. The FEA method is espe- testing. Given a resonant AE sensor with 10.5 kV s/m
cially valuable for modeling interior AE sources as these peak sensitivity at 200 kHz (−70 dB in reference to
cannot be simulated experimentally. Figure 30.6 shows 1 V μbar−1 ), a 1 μV signal corresponds to a 0.1 fm
a result of Lamb wave propagation of 50 mm from a fi- surface displacement over 1 μs. Since a preamplifier
nite crack source at the mid-plane in a carbon-fiber has the input noise of 0.6 μVrms , this signal is at the
composite plate. This signal essentially comprises the detection limit. Another method to enhance the sen-
symmetric Lamb wave mode as the crack opening dis- sitivity is to place a high impedance amplifier within
placement is in the direction of the propagation [30.24]. the sensor housing. This eliminates the effects of ca-
ble capacitance, allowing the use of long sensor cables.
30.2.2 Sensors The frequency responses of AE sensors are usually
characterized (face-to-face) against a secondary stan-

Part H 30.2
Acoustic emission sensors typically employ a disk of dard using compressional waves at normal incidence.
piezoelectric ceramic or crystal and respond to velocity For many applications, however, surface or plate waves
or acceleration normal to the face of a sensor. One type are dominant and their movements normal to the sur-
has a broadened frequency response using a backing face are detected, and the size of a sensor affects its
material behind a transducer element. This construction responses through the aperture effect. Proper sensor se-
is common to that of the ultrasonic transducers. Another lection for frequency ranges or wave modes improves
type enhances the sensitivity by using the thickness the sensitivity of AE detection. For concrete, rocks,
and/or radial resonance of a transducer element with- and geotechnical applications, low frequency sensors,
out using a backing material. These are resonant or such as geo-phones, hydrophones, and accelerometers
narrowband sensors and are employed most often in are also used. These can have flat frequency responses
AE testing because of their high sensitivity. Typical and some have good directionality, allowing the con-
resonant AE sensors have peak velocity sensitivities struction of tri-axial sensors [30.2–6].
1214 Part H Engineering Acoustics

Sensor response (dB) (relative to 1 V/nm) Sensor response (dB) (relative to 1 V/nm)
20 20
a) Glaser b) PAC R15
0 0

–20 –20

–40 –40

Position 1 - ball drop Position 1 - ball drop


–60 Position 1 - capillary –60 Position 1 - capillary
Position 2 - ball drop Position 2 - ball drop
Position 2 - capillary Position 2 - capillary
–80 –80
101 102 103 101 102 103
Frequency (kHz) Frequency (kHz)
Sensor response (dB) (relative to 1 V/nm) Sensor response (dB) (relative to 1 V/nm)
20 20
c) PAC NANO30 d) DW B1025
0 0

–20 –20

–40 –40
Position 1 - ball drop
Position 1 - ball drop Position 1 - capillary
–60 Position 1 - capillary –60 Position 2 - ball drop
Position 2 - ball drop Position 2 - capillary
Position 2 - capillary Velocity ref. line
–80 –80
101 102 103 101 102 103
Frequency (kHz) Frequency (kHz)

Fig. 30.7 (a) Frequency response of a conical sensor of Glaser design showing flatness over 10 kHz to 1 MHz. (b,c)
Narrowband AE sensor responses for PAC-R15 and PAC nano30. (d) A broadband velocity response of DW B1025
(after [30.37])

Surface displacements are also measured using a ca- under test is placed at a symmetric position to the ca-
pacitive sensor or a laser interferometer. Both serve an pacitive sensor standard (or a laser interferometer). For
important role in sensor calibration, although these are a working calibration of the AE measuring system, the
still impractical for field use due to difficulty of han- breaking of pencil lead (0.3 ≈ 0.5 mm outer diameter)
Part H 30.2

dling and surface preparation (capacitive sensor) and to has been used effectively. This is known as the Hsu–
their large size, high cost, and low sensitivity (interfer- Nielsen source and generates ≈ 1 N force drop over
ometer). A primary sensor calibration system has been a 1 μs period [30.36].
constructed using a capacitive sensor in combination High-fidelity capture of signal waveforms is needed
with a large steel block and a mechanism to break a fine for specialized studies of AE sources. A special sensor
glass capillary (≈ 0.2 mm outer diameter) [30.34, 35]. design based on a truncated conical element achieves an
The breaking of the glass capillary produces a sudden exceptional fidelity in the surface displacement detec-
release of force (≈ 20 N within a few tenths of μs) and tion. Proctor at NBS (now NIST) used a small element
provides a reproducible source of body waves and sur- with matched backing and obtained a flat (±3 dB) re-
face waves that match well with theoretical predictions. sponse to 2 MHz [30.38]. This design has been refined,
Peak surface displacements of ≈ 0.15 nm are gener- reduced in size to that of a conventional sensor and
ated at 0.1 m from the capillary break. Here, a sensor ruggedized, thus joining the rank of practical AE sen-
Acoustic Emission 30.3 Source Location 1215

sors [30.29, 37]. The frequency response of the most In addition, the distributions of peak amplitude,
recent design by Glaser exhibits exceptional flatness in rise time, and duration are also obtained, as well
over 10 kHz to 1 MHz, as shown in Fig. 30.7a [30.37], as arrival time differences of burst emissions at dif-
which also shows two other narrowband AE sensor re- ferent sensors [30.1–7]. Frequency-based parameters
sponses with resonances (Fig. 30.7b,c) and a broadband are also useful. These include peak frequency, me-
velocity response (Fig. 30.7d). dian frequency, spectral centroid (or mean frequency),
and partial powers for various frequency bands. These
30.2.3 Signal Characterization signal parameters can be acquired in real time with
dedicated hardware. The duration of typical burst emis-
Characteristics of the acoustic-emission signals in com- sions is 0.1–1 ms, however, at most several thousand
mon use are: signals per second can be distinguished from a sensor.
For higher rates of emissions, average intensity mea-
1. AE event count (and AE event rates): the number surements are utilized. By recording acoustic-emission
(and rates) of burst-type emissions (in multisensor signals digitally, the power density spectrum or more
AE detection systems, the term hit is used in place commonly frequency spectrum and shape parameters
of event since a single AE event can reach more than of the signal waveforms can be utilized. Peak intensity
one sensor and is counted each time). and position in the frequency domain, shifts in dominant
2. The averaged signal intensity of continuous-type frequency over time and rates of rise and decay of the
emissions (e.g., root mean square (rms) voltages of waveform are the features of importance. Their values
amplified signals). diminish when narrowband sensors are used. These fea-
3. The peak amplitude. tures are also used in constructing intelligent classifiers
4. Rise time. of pattern recognition analysis [30.23, 25, 39]. Com-
5. Duration of burst emissions (defined with the binations of these and other test parameters, such as
threshold). applied force or pressure, time under load, and ground
6. The signal strength of burst emission (area of the tilt and displacement are used to evaluate the nature of
signal envelope, Fig. 30.1 for the definition of 3.–5.). AE sources.

30.3 Source Location


A major goal of acoustic-emission testing is to deter- to cover an area of a few square meters with several
mine the location of active flaws in a structure. AE sensors and as many sets as required are utilized to
testing uses the structure itself to discover disconti- monitor the critical zones of a large bridge, for exam-
nuities through the generation and propagation of AE ple [30.42].
signals, which can be continuous (e.g., fluid/gas leaks Source location utilizes two general approaches,
and fretting) or burst emissions (e.g., metal fracture and i. e., zone location and discrete source location. In the
delamination of composites). Two sensors are used to zone location method, a source is presumed to exist
locate the source in a linear structure such as a pipe and within the zone that belongs to the sensor receiving

Part H 30.3
a tube (linear location). More sensors are needed when the first hit signal or receiving the strongest AE signal
the linear structure becomes longer or when two or (typically in peak amplitude). This method is suited for
three-dimensional structures are examined. Figure 30.8 locating leaks (continuous emissions) and for sources
shows typical sensor placements on a storage tank when in a highly attenuating medium (fiber composites and
complete coverage is desired in AE testing [30.40, 41]. metals coated with viscous insulation). This method
In most applications, the structures can be regarded can be refined by determining which sensor receives
as a two-dimensional shell structure, and the surfaces the second-hit signal or the second strongest signal.
can be laid out on a plane. For example, a spherical In zone location, the zone around each sensor is sub-
tank can be represented by an icosahedron and by 20 divided, and the number of the subdivision is equal
triangles on a planar display. This method can also to that of surrounding sensors. When the amplitudes
be applied locally on large structures, when expected of the signals received are measured, further improve-
damage locations can be anticipated. It is common ments in source location accuracy are possible through
1216 Part H Engineering Acoustics

29.9 m a) Sensors b)

8 mm

7.0 m

26.3 m 7.0 m

7.0 m
11.4 mm
2.6 m –90° view – Back view 90° view – Front view
= AE sensor Locations of energetic events
5.9 m 16 sensors
(Typ) Each row Fig. 30.9a,b Distribution of energetic acoustic-emission
(64 total)
events in a 24 h period before the final fracture. Kevlar
Fig. 30.8 Typical acoustic-emission sensor placements on composite overwrapped pressure vessel (COPV) (af-
a storage tank (after [30.40, 41]) ter [30.43])

an interpolation technique by taking the attenuation into field. The accurate determination of signal arrival times,
account [30.40, 41]. or signal onset, is also important in assuring good
In a discrete source location, the full spatial co- source location. Several automatic onset pickers have
ordinates of an AE source are defined by measuring been incorporated, but one based on the Akaike infor-
the differences in arrival times of AE signals at mul- mation criterion is best suited for AE signals [30.6].
tiple sensors. The AE signals must be burst-type and Another important source location approach uses ori-
strong enough to reach three or more sensors. In atten- entation and propagation-mode dependence of wave
uating media, the sensor spacing must be sufficiently velocity [30.45–47], in particular, those of plate waves
small. Generally, the wave velocity is assumed constant that are dominant in thin composite structures [30.48].
and triangulation techniques are used. A pair of sen- In order to evaluate the severity of an AE source,
sors defines an arrival time difference and a hyperbola the intensity and activity of the source and its proxim-
passing through a source. The location of the source ity to neighboring sources are determined. This requires
can be obtained as the intersection of two such hyper- the collection of additional data on the AE sources and
bolae. Hundreds of sources per second can be located typically involves post-test analysis. Such data include
by typical AE instruments. For this method to be prac- the presence of high amplitude emissions, AE activities
tical, the attenuation through the structure cannot be during load hold, those during stress increases, and Fe-
high to avoid the use of excessive sensors and signal licity ratios (FR) during load cycling [30.49]. Statistical
processing channels. Emission rates must be moderate analysis, e.g., amplitude distribution, of AE signals re-
so that the arrival time differences of a single event ceived at individual sensors is also useful. An example
can be detected without interference of the next event. of a located source display is given in Fig. 30.9. This
Part H 30.4

Several source location algorithms are available in mod- spherical vessel is a carbon-fiber composite, subjected
ern AE systems for optimizing the results [30.44, 45]. to stress rupture testing. Clusters of energetic events
A number of more sophisticated algorithms from seis- were detected in the final day of a 250-day test prior
mology are also adopted, especially in the geotechnical to failure [30.43].

30.4 Sources of Emissions and Materials Behavior


Plastic deformation of most structural alloys gener- ening (4340 steel; Fig. 30.10) [30.50–52]. AE from
ates acoustic emission that reaches a maximum at or plastic deformation is due to dislocation motion, and
near the yield stress and diminishes with work hard- AE signals are of the continuous type. Purely elastic
Acoustic Emission 30.4 Sources of Emissions and Materials Behavior 1217

Vrms (µV) Stress (GPa) Stress (MPa) AE rms voltage (µV)


3 1000
4340 steel
1.2 20
800
2
a) b)
600
0.6 Stress
1 10
400

¼ ½1 5 10 15 20 AE
Strain (%)
0 0 200
0 10 20
Nominal strain (%)
Fig. 30.10 Acoustic-emission behavior of 4340 steel, oil 0 0
quenched and annealed at 600 ◦ C. Acoustic-emission in- 0 1.25 2.5 0 1.25 2.5
Crosshead displacement (mm)
tensity is measured using rms voltages. See insert for strain
values (after [30.52]) Fig. 30.11 (a) Acoustic-emission behavior of A533B steel,
quenched and tempered at 550 ◦ C. Loaded in short
deformation produces no AE. Once the work hard- transverse orientation, showing inclusion-induced acous-
ening begins, the AE activities subside and the rms tic emission in the elastic region. (b) Immediate reloading
voltage is only slightly above the background with occa- after the first loading in (a). Kaiser effect is observed (af-
sional spikes due to burst emissions (Fig. 30.10). These ter [30.53])
burst emissions originate from microcracks or from
the fracture and decohesion of nonmetallic inclusions. 30.4.1 Plastic Deformation of Metals
The latter is active in short transverse loading, even
from the preyield elastic region (Fig. 30.11a) [30.53]. Figure 30.12 shows AE behavior of a copper single
In some alloys, twinning produces burst-type AE. crystal, deformed at 300 K [30.54]. The stress–strain
At high temperatures where work hardening is low, plot shows typical three-stage behavior, while AE en-
the AE signal intensity remains strong even at high ergy peaked at the start of Stage II. Median frequency
strains. was ≈ 250 kHz in Stage I; it increased with decreas-

10 6 600
Stress σ (MPa)

AE energy (µV2 s)

Median frequency fmed (kHz)

Stress
AE energy
5
8 AE median frequency
500

Part H 30.4
4
6
3 400
4
2
300
2
1

0 0 200 Fig. 30.12 Acoustic-emission be-


0 0.1 0.2 0.3 0.4
Strain ε havior of a copper single crystal
deformed at 300 K (after [30.54])
1218 Part H Engineering Acoustics

ing AE energy in Stage II and jumped at Stage III. This Dynamic strain aging or the Portevin–Le Chatelier
trend developed from the reduced glide distance of dis- effect produces repeated load drops from the locking
locations with work hardening and the resultant increase and unlocking of gliding dislocations. This effect is
in the number of glide loops. Solid solution alloying prominent at room temperature in Al alloys, while in
shows a reduction in the intensity of AE, which is at- steels, it causes so-called blue-brittleness at ≈ 300 ◦ C.
tributed to the raised frictional stress due to solution These load drops or serrations result in AE intensity
hardening, which in turn increases median frequency as fluctuations [30.50, 51]. Similarly, Lüders deformation
more dislocations are needed to account for the reduced in steel also exhibits high AE activity, as shown in
dislocation velocity [30.54, 55]. Fig. 30.10. Lüders deformation, however, occurs only
Acoustic emission phenomena are irreversible. once at the start of yielding.
When a sample is deformed, unloaded, and reloaded, Inclusions and second phase particles are another
it emits no AE until the previously applied load is important origin of AE during deformation. Inclusions
exceeded. This is known as the Kaiser effect. This be- are significant AE sources during tensile loading of
havior is illustrated in Fig. 30.11a,b where a sample was steels in the short-transverse direction and of most high
loaded, unloaded, and reloaded immediately [30.53]. strength Al alloys. In steels, decohesion of MnS in-
The Kaiser effect is useful for the determination of clusions is the most important (Fig. 30.11a). These are
a prior loading level, but it is not permanent. Extended burst-type emissions and their number is proportional
holding and/or annealing before the second loading may to the inclusion content. Inclusion-induced AE exhibits
reduce the load at which AE starts to be emitted again. anisotropic behavior, i. e., the strongest AE activities are
Microstructural variation affects the AE behavior. found in the short-transverse direction and the lowest in
When a metal or alloy is cold worked, the AE ac- the longitudinal direction. In many Al alloys, the frac-
tivity is suppressed; often it is eliminated completely ture of Al-Si-Fe and other nonmetallic inclusions causes
as these have high dislocation densities, which limits most AE observed, often masking the AE activity at
glide distances. When the grain size is reduced, AE in- yielding. Here, inclusion-induced acoustic emission is
tensity often increases along with the strength. Other of continuous-type, since many small particles con-
factors may, however, override the grain size effect. tribute to the overall activity [30.17, 18, 50, 51].
In most precipitation-hardened alloys, AE intensity de-
creases with aging. In Al alloys, peak AE intensity at 30.4.2 Fracture and Crack Growth
yield decreases by more than a factor of 3 from the
solution-treated condition to the fully aged condition. Most materials and structures produce large, audible
When alloys are strengthened by the addition of disloca- sounds during final fracture. In high strength materials,
tions or hard precipitates, the mean free path of mobile strong elastic waves are generated during cracking. AE
dislocations is reduced. When an individual glide mo- can be detected long before final fracture and can be
tion of the mobile dislocations is restricted, the AE utilized in preventing catastrophic failures of engineer-
intensity diminishes even though the number of such ing structures. This application has been and remains
mobile dislocations increases, raising the median fre- the major driving force of AE technology develop-
quency [30.17, 18, 50, 51]. ment [30.1, 20].
The test temperature affects the AE behavior of ma- Brittle solids under tension or in bending, including
terials undergoing plastic deformation. In pure metals ultra-high strength steels and ceramics, often generate
Part H 30.4

and dilute alloys, the peak AE level at yield initially in- only a small number (< 100) of AE signals just be-
creased by 50 to 100% with the test temperature, but fore final fracture [30.17, 18]. Subcritical crack growth
decreased above T/Tm of 0.3–0.4, where Tm is the ab- is minimal, which limits the AE activities. This be-
solute melting temperature. In normalized steels, the havior is unfortunate because these materials are most
AE level at yield increased fivefold over −150–150 ◦ C, likely to fail suddenly and the need for preventing such
while the yield strength decreased by 30%. AE from failures is the greatest. However, all the microfracture
austenitic stainless steels increased 10–20 times from mechanisms that are operative in these materials, i. e.,
room temperature to 1000 K, where the AE level cleavage, quasi-cleavage, and intergranular fracture, can
reached a maximum. The large changes in stainless be detected easily since a large fraction of the AE events
steels appear to reflect an increase in the stacking fault have peak amplitudes above 1 mV or 60 dB, in refer-
energy, thus altering the slip mode from planar to non- ence to 1 μV at the sensor. (This is often denoted as
planar with increasing test temperature [30.17, 18]. 60 dBAE .) In some brittle materials, subcritical crack
Acoustic Emission 30.4 Sources of Emissions and Materials Behavior 1219

log ΣNAE Acoustic emission event counts


5 2000

4
200
Brittle steel
b=1
Alumina
3
20
HT80 Ductile steel
2 b = 1.65

SNCM8 2
0.01 0.1 1 10
1 Peak amplitude (mV)
D6ac Fig. 30.14 Amplitude distribution of burst AE of A533B
0 steel for brittle (quenched) and ductile (tempered) condi-
0 1 2 3 tions (after [30.56])
log KI (MPa m)
Fig. 30.13 Acoustic-emission event counts increase with volved. That is, in addition to those mentioned above,
stress intensity factor low energy tear, alternating shear, and microvoid coa-
lescence are observed. Again, AE event counts increase
growth (or the fracture process zone ahead of the crack with the stress intensity factor according to (30.2) with
tip) is found. During subcritical crack growth, AE event higher m values of 3–20 (Fig. 30.13) and a power law
counts increase in proportion to the m-th √ power of stress amplitude distribution of (30.3) with b = 0.7–1.5. The
intensity factor K I , which is equal to Y σ a, where Y is exponent m often increases as K I approaches the frac-
a geometrical factor, σ stress, and a the crack length; ture criticality. Transition in microfracture mechanisms
can be reflected more clearly by plotting cumulative
Nc = A(K I )m , (30.2) AE energy against JI (Fig. 30.15). Here, AE energy is
defined as the square of the peak amplitude, and JI
where Nc is the cumulative number of AE events and A
is given by (1 − ν)K I2 /E, where E and ν are Young’s
is a constant. The cumulative amplitude distribution of
modulus and Poisson’s ratio. The transition is sharp
such AE signals can be approximated by a power-law
distribution of the form,
log EAE (mV2)
Nc = B(Vp )−b , (30.3)
3
where Vp is the peak amplitude, and B and b are
constants. In low toughness materials (e.g., alumina) 4340-Q 4340-6
showing cleavage and intergranular fracture, m = 4.
In steels, m varies from 2.5 to 10 (Fig. 30.13). The 2024 Al

Part H 30.4
2 0.5 Mo
values of b in brittle materials (alumina, quenched
steels) are 0.5–1, while ductile steels showed b of 1–2
(Fig. 30.14) [30.17, 18, 56]. When plastic flow occurs at SNCM8
the crack tip or when inclusion failure occurs, different 1
distribution laws (Weibull types) were found [30.56].
When the J-integral (JI ) values increase from 2 to A533B
200 kN/m, as in high strength Al and Ti alloys and in
high strength steels, AE signals are produced as the 0
plastic zone ahead of the crack tip expands. AE ac- 0 1 2
log JI (kN/m)
tivity becomes significant with many high amplitude
emissions (> 60 dB) when the crack starts to grow. In Fig. 30.15 Cumulative AE energy against JI for steels and
this stage, various mechanisms of microfracture are in- 2024 Al (data from [30.17] and others)
1220 Part H Engineering Acoustics

when cleavage microcracks initiate as in SNCM8 and of inclusions (especially in Al alloys) also produce AE
as-quenched 4340 steels (4340-Q), but is also visible events. Still, even the maximum AE intensity due to
when fibrous microfracture begins as in 2024Al, 0.5Mo, inclusions is less than that from brittle fracture in low
A533B, and quenched and tempered (at 600 ◦ C) 4340 toughness materials. This inclusion effect is strongest
(4340-6) steels [30.17, 18]. in samples stressed in the short-transverse direction.
Higher fracture toughness materials typically fail The total counts at the maximum load for the short-
under plane stress conditions by microvoid coalescence transverse samples are 20–50 times that of longitudinal
and shear mechanisms with some tearing. In these duc- samples of the same steel.
tile solids, the expansion of plastic zones ahead of Fatigue leads to eventual fracture in a number
the crack tip initially generates AE, with AE activ- of engineering structures under repeated loading. AE
ity reaching a maximum at general yield just like the accompanies fatigue crack initiation and subsequent
AE behavior of plastic deformation. This is the weak- growth, showing rapid rise just before final fracture.
est among fracture-related AE with a peak amplitude As shown in Fig. 30.16, AE activity is low in Region
of < 40 dBAE . Beyond the general yield, stable crack II (the Paris law) fatigue crack growth. As Region III
growth processes begin. It is often difficult to detect this fatigue begins, AE counts rise [30.57]. Here, SUJ2 high-
by AE, as the AE amplitude is still low (< 60 dBAE ), strength steel was examined and da/ dN matches the
which reflects the high microscopic ductility of the established Paris law. The absence of AE in Region I
materials. is natural, as even fatigue striations are not found at
In moderate to high fracture toughness materials, these low K max levels. In [30.57], the√crack was trans-
nonmetallic inclusions exert a substantial influence on granular until K max exceeded 8 MPa m (near Region
the AE behavior. The decohesion of MnS inclusions III). Above this level, the crack became intergranu-
emits moderately strong AE (a peak amplitude of lar and AE activity increased. Often, the detection of
< 55 dBAE ) from the early part of elastic loading and is AE precedes an optical observation of a fatigue crack,
the primary source of strong emissions in ductile steels. but initial stages of fatigue are hard to detect because
This is shown as AE in the nominally elastic loading of attendant noise under typical cyclic loading condi-
range in Fig. 30.11a [30.53]. Plastic flow and fracture tions. In cyclically loaded structures, similar trends have
been found. For welded steel cruciform under cyclic
loading, da/ dN and dU/ dN (= integrated AE en-
Crack growth rate da /dN (m/cycle) Cumulative AE counts
1000
10–6 log(da /dN), log(dU/dN)
8
log(dU/dN) = 6.09 log(ΔK) – 6.65
6 log(da/dN) = 3.37 log(ΔK) – 9.72

10–7
4

500 2

10–8 0
Part H 30.4

AE counts –2
Region II total 587
10–9 –4

Region III –6
0
3 4 5 6 7 8 9 10 20
Maximum stress intensity factor Kmax (MPa m) –8
0.8 1 1.2 1.4 1.6
log(ΔK)
Fig. 30.16 Fatigue crack growth rate ( da/ dN) and AE
(event) counts against K max for SUJ2 steel f = 20 Hz, Fig. 30.17 Fatigue crack growth rate ( da/ dN) and AE en-
R = 0.1. : ΔK increasing test; : ΔK decreasing test; ergy per cycle ( dU/ dN) follow power laws against ΔK
solid line: da/ dN = 1.35 × 10−10 ΔK 2.25 (after [30.57]) (after [30.58])
Acoustic Emission 30.4 Sources of Emissions and Materials Behavior 1221

ergy per cycle) follow similar power laws against ΔK behavior of brittle solids. Near the final fracture, high
(Fig. 30.17) [30.58]. amplitude, long duration signals from splitting are also
Once a crack develops, different types of AE are observed. Delamination occurs when reinforcement
emitted as a function of loading cycle phase: layers (called plies) have different fiber orientations or
notches. AE signals from delamination are the strongest
1. Near a peak tensile load, AE due to crack growth
(50–130 dBAE peak amplitude) and have the longest
and inclusion fracture is observed.
duration (0.1–10 ms) [30.59].
2. As the load is reduced to zero, crack closure noise
Most composite structures are fabricated with mul-
is detected as AE, i. e., AE from crack face fretting
tiple plies with various combinations of reinforcement
and crushing of oxide particles.
orientations. When they are stressed, complex stress
3. As the load increases again, crack faces that had
patterns develop between reinforcing fibers and plies,
stuck together separate, producing AE.
and copious emissions are generated, mainly from
All three types of fatigue AE can be used in de- the transverse matrix cracks and delamination. Dis-
tecting the presence of a fatigue crack. Peak load AE crimination of individual AE signals relies on peak
contributes less than 10% of the total AE activity in amplitude, rise time, and duration. Damage indications
some cases, but more when high stress ranges are used. in glass fiber composites include high amplitude emis-
Initially, AE events are detected over a wide range of sions (> 70 dBAE ), long duration signals, and emissions
loading, but tend to concentrate at the maximum load during load hold periods. However, signal discrim-
toward the end of fatigue loading. For the detection of ination is often difficult because of high rates of
fatigue cracking, frictional AE due to fretting and crack emissions and strong signal attenuation. The use of
face separation are important. In addition, particles of pattern recognition analysis is essential to differentiate
oxides and various corrosion products often form be- various sources [30.25, 39].
tween the crack faces. Their subsequent fracture also When a composite sustains damages, the Kaiser ef-
contributes to AE due to fatigue [30.1]. fect is no longer observed. FR is defined as a ratio of
the load, at which AE is observed upon reloading, to
30.4.3 Fiber Fracture and Delamination of the maximum prior load. FR is 1.0 or higher when the
Composite Materials composite is sound and decreases after severe loading.
As shown in Fig. 30.18, FR drops to 0.75 by stress-
Most composite materials in current use are rein- ing to 80% of the fracture load in glass and carbon
forced by glass and carbon fibers, which take various
forms, such as short random fibers, mats, woven rov-
Felicity ratio
ings, and continuous fibers. Aerospace composites use
higher modulus carbon and aramid fibers. Matrix ma-
terials include thermosetting plastics (polyester and 1
epoxy) and thermoplastics (polypropylene and polysul-
fone). These resin-matrix composites are difficult to
inspect with conventional nondestructive test methods
and AE has been used widely. Main sources of emis- 0.9
sions are fiber fracture, delamination (matrix cracks

Part H 30.4
between reinforcement layers), splitting (matrix cracks
parallel to fibers), and transverse matrix cracks [30.59].
0.8
When unidirectionally reinforced composites are
Carbon fiber (UD)
stressed, fiber fracture and matrix cracks contribute to Carbon fiber composite
AE. Glass fibers generate high amplitude emissions Glass fiber composite
(> 70 dBAE ) just prior to composite fracture (> 90% 0.7
of the fracture load). Carbon fibers start to fracture lo- 40 50 60 70 80 90 100
Stress/fracture strength (%)
cally above 50% of the fracture load of the composites
and produce low amplitude (30–60 dBAE ) emissions, Fig. 30.18 FR versus applied stress normalized by the frac-
which reflects their smaller diameters and lower frac- ture load in glass and carbon fiber reinforced composite
ture strain. The rate of emissions increases rapidly as vessels. Results for unidirectional carbon fiber composite
the final fracture load is approached, similarly to the retains high FR (data from [30.59] and others)
1222 Part H Engineering Acoustics

fiber reinforced composites. Such damage depends on


Felicity ratio
1 the ply sequence and is less in simpler ply structures;
FR3 = 0.0172 PI + 0.5 a unidirectional carbon fiber composite retains high fe-
(r2 = 0.342) licity ratios (> 0.9) up to 95% of the fracture load. The
0.9
FR2 = 0.0219 PI + 0.381 Felicity effect is a valuable tool in assessing compos-
(r2 = 0.914)
ite damages. An example is shown in Fig. 30.19, where
0.8 burst pressure-Felicity ratio correlation is given [30.60].
(D)
This applies to Kevlar-overwrapped pressure vessels,
0.7 which shows that this ratio can predict burst pressure
from AE testing at lower stress levels. While several
Cycle 2 other AE parameters have been used for this purpose
0.6 Cycle 3
since the earliest days of AE technology, the Felicity ef-
fect appears most promising. Yet a number of factors
70 80 90 100 110 120 130
influence FR ratio at burst, and more work is needed, as
Failure strength, PI (MPa)
is reviewed in [30.59].
Fig. 30.19 Burst pressure–felicity ratio correlation for
Kevlar COPV with different levels of impact damage (af- 30.4.4 Rock and Concrete Fracture
ter [30.60])
AE monitoring for mine safety is the oldest applica-
tion and started in the 1930s at the US Bureau of
Mines [30.2–6]. Rock fracture initiates throughout the
a) Deviatoric stress (MPa) Velocity (m/s)
650 6000
stressed region from uniformly distributed microcrack
A B C D E F nucleation. This stage corresponds to AE source loca-
520
5500 tions spread over the entire sample. At close to peak
stress, faults nucleate and propagate by the interaction
5000
390
of tensile microcracks, when a clustering of AE occurs
Deviatoric stress
Velocity 4500 and leads to an expanding fracture nucleus with concen-
260
trated AE activity. This becomes the fracture process
4000 zone of intense tensile cracking, followed by a region
130 of shear cracking [30.61]. These stages are shown in
3500
Fig. 30.20, where microcracks develop in A and B (ac-
0 3000 companied by 30% drop in sound velocity), the fracture
0 11 500 23 000 34 500 46 000 57 500 69 000 nucleus begins at C, and final fracture at F. Observed
Time (s)
AE locations for B, D, and F are indicated in the bottom
b) row. AE signal characteristics varied with crack devel-

Deviatoric stress (MPa) b-value


645 3.5
A B C D E
Part H 30.4

3
2.5
545
2
1.5
445 Deviatoric stress
B) 5100 –18 540 D) 31 950 – 58 500 F) 62 820 – 69 300 b-value 1
Time (s)
0.5
Fig. 30.20a,b Loading curve in deviatric stress and sound velocity 345 0
versus time for Westerly granite (a). Microcracks develop in A and 355 385 415 445 475 505 535
Time (s)
B with 30% drop in sound velocity. Fracture nucleus begins at C
and D. Final fracture at F. (b) Observed AE locations for B, D, and Fig. 30.21 AE signal characteristics, b values, decreased
F given in the bottom row (after [30.61]) with crack development (after [30.61])
Acoustic Emission 30.4 Sources of Emissions and Materials Behavior 1223

Fig. 30.22 AE behavior of concrete


Load (kN) Number AE events
60 600
under repeat-loading (after [30.3])

50 500

40 400

30 300

20 200

10 100

0 0
9:35:00 9:55:00 10:15:00 10:35:00 10:55:00 11:15:00 11:35:00 11:55:00 12:15:00 12:35:00
Time (hh:mm:ss)

opment, which is revealed clearly in the decrease of b decreases to 0.3 at the seventh loading. This AE dur-
values, as shown in Fig. 30.21 [30.61]. The b values ing unloading is useful in concrete damage evaluation.
are above 1.5 until shear cracking develops and drop A calm ratio for a load cycle is defined as (unloading
suddenly when fracture is imminent. A similar trend AE activity)/(total AE activity of the particular load cy-
in b values was found in steel fracture, as noted in cle) [30.33]. In this case, it started to rise at the fourth
Sect. 30.4.2. cycle (≈ 0.1) and reached a high value of 0.27 at the
Concrete fracture is similar to that of rock above. seventh cycle. A low load ratio and a high calm ratio are
Here, tensile microcracks initiate at large aggregates indicative of severe damage, while a high load ratio and
that are mixed with a mortar matrix. At a later a low calm ratio correlate to minor damage, as shown
stage of fracture, shear cracks become dominant from in Fig. 30.23 [30.33]. The frictional origin of AE during
the shearing of crack surfaces. This shearing/fretting unloading is manifested as low average frequency and
also contributes to AE during unloading in cyclically long duration of AE signals.
stressed concrete. The AE behavior of concrete under
repeat loading is shown in Fig. 30.22 [30.3]. AE events 30.4.5 Other Emission Sources
increase with load and even during unloading beyond
the fourth loading. The Felicity effect is found im- Acoustic emission is observed under corrosion from hy-
mediately from the second loading and the load ratio drogen evolution, pitting, and exfoliation, but anodic
(this term is used in the concrete field in place of FR) metal dissolution produces no AE. When materials are
subjected to stress corrosion or hydrogen environments,
they produce AE by a number of different mechanisms,
Calm ratio including film breakage, hydrogen-induced cracking,
inclusion and particle fracture at the crack tip, and
Heavy
plastic deformation. The detection of hydrogen em-

Part H 30.4
0.15 damage
brittlement is one of the early applications of AE
techniques. During crack propagation due to hydrogen
0.1 embrittlement, high amplitude emissions are observed
and can be distinguished easily from the active path cor-
rosion process. The latter generates only a small number
0.05 of low amplitude emissions. The crack growth rate for
Intermediate Minor
damage damage stress corrosion cracking shows a three-stage behav-
0 ior with respect to the K I applied; that is, an initial
0 0.2 0.4 0.6 0.8 1 1.2 1.4 increase above a threshold K I , followed by a region
Load ratio
with a nearly constant rate and the final rise near the
Fig. 30.23 Concrete damage classification using the load critical K I . AE activities follow a similar trend [30.18,
and calm ratios of AE activity (after [30.33]) 62].
1224 Part H Engineering Acoustics

An exceptional stress corrosion AE involving poly- be located by AE in real time or in post-tests and
thionic acid and stainless steels should be noted. This further evaluated by other nondestructive test meth-
industrially important corrosion occurs via active path ods [30.1].
dissolution, yet very strong AE bursts are emitted from Monitoring of various machining or metal removal
the ejection of individual grains (also called grain drop- processes detects tool wear, tool fracture, and cutting
off) [30.62, 63]. Simultaneous monitoring of AE and conditions. These are based on AE due to friction be-
corrosion potential fluctuation helps clarify operative tween tool and chips or a workpiece, abnormal signals
corrosion mechanisms [30.63, 64]. from chipped tools, plastic deformation, and fracture
AE monitoring of welding processes can locate of chips. This application is important with automated
weld cracks and slag inclusions and find the depth manufacturing processes. Other important AE sources
of weld penetration and mistracking. Expulsion and in metals include: martensitic transformation, solidifi-
lack of welds in spot-welding can also be detected. cation (hot cracking), oxidation (oxide cracking and
These in-process monitoring methods may avoid elec- spalling). Other sources are gas and fluid leakage, mag-
trical welding noise by using guard sensors and gating netization (AE equivalent of the Barkhausen effect),
circuits synchronized to the welding steps. Evalu- corona discharges in power transformers, and friction
ation of welds has been the primary goal of AE and rubbing noise from rotating machinery. AE also is
monitoring of welded structures, such as pressure ves- used in detecting crack initiation during scratch testing
sels, tanks, and highway bridges. Defective welds can of thin films [30.1, 18].

30.5 Structural Integrity Monitoring


Modern AE technology grew from the need to in- tude events. Emissions during hold indicate continuing
spect glass-fiber reinforced rocket motorcases in the permanent damage and a lack of structural integrity.
1960s [30.65]. It developed rapidly and was used ex- For in-service vessels, an FR criterion (when it is less
tensively in the US space and defense industries. The than 0.95) is an important measure of previous dam-
use of AE in the chemical industry followed. AE testing age. The historic index is a sensitive measure to detect
procedures of fiber reinforced plastic vessels and piping a sudden increase in signal strength. Large severity val-
have been standardized [30.40, 41, 49, 59, 66]. ues result from delamination, adhesive bond failure,
and crack growth. High amplitude events indicate struc-
30.5.1 Fiber-Reinforced Composite Pressure tural (glass-fiber) damages, especially in new vessels.
Vessels, Tanks, and Piping AE testing of these tanks and vessels has been highly
successful over the last three decades.
Test vessels and piping are typically pressurized to A recent technical challenge to AE testing is
110% of the maximum allowable working pressure the inspection of small, but extremely high-pressure
to locate substantial flaws. Using the zone location (100 MPa hydrogen) cylinders. The AE-based ASME
method, AE activities of flaws within each zone are de- Code Case has now been developed to provide the
tected and the zone represents the approximate position accept-or-reject criteria using the curvatures of cumula-
Part H 30.5

of these flaws. Sensors are positioned to detect struc- tive events and energy curves [30.67–69]. Another prob-
tural flaws at critical sections of the test vessel, i. e., lem for composite tanks is the inspection of liquefied
high stress areas, geometrical discontinuities, nozzles, natural gas (LNG)/compressed natural gas (CNG) tanks
and manways. Pressurization in AE testing of a ves- as well as self contained breathing apparatus (SCBA) air
sel proceeds in steps with pressure hold periods with tanks. Technically, AE can be used for certain. However,
depressure increments. A test is terminated whenever testing these tanks at low cost to assure extended use life
a rapid increase in AE activities indicates an impending is yet to be resolved. One other challenge is the long-
failure. Detected flaws are graded using several crite- term uses of composite tanks and how to assure/estimate
ria, including emissions during pressure hold periods, their remaining life. Figure 30.24 shows the stress rup-
FR, historic index (average signal strength of recent ture life of three types of composite strands [30.70–73].
events divided by that of all events), severity (average The poor stress rupture property of glass fibers is un-
signal strength of ten largest events), and high ampli- derstandable, but even aramid (Kevlar) fiber loses 1/4
Acoustic Emission 30.5 Structural Integrity Monitoring 1225

Ultimate tensile strength (%) Ch.1 0° Thickness (mm)


100 8.4–8.6
10% Specimen failure lines 8.2–8.4
Ch.8 Ch.2 8–8.2
90 7.8–8
7.6–7.8
80 e 7.4–7.6
7.2–7.4
Ch.7 Ch.3
70 270° 90°
Carbon (T-50S) a
60 Kevlar b d
S-glass
Ch.6 c Ch.4
50 –2
10 10–1 100 101 102 103 104
Time to failure (h) Ch.5 180°

Fig. 30.24 Stress rupture data for three types of fiber com- Fig. 30.25 Tank bottom thickness data (in color) and ac-
posite strands (data from [30.70]) tive AE clusters (a–e). Two AE clusters at a and b matched
well with thinned spots in the third quadrant. No AE was
its strength in a few hundred hours. Recent stress rup- detected from a spot between Ch. 1 and 8 at 340 ◦ C (af-
ture data for Kevlar-overwrapped pressure vessels show ter [30.74])
comparable behavior to that of Kevlar strands [30.70–
72]. While AS-4 carbon fiber strands are comparable tice, the located flaws are usually confirmed by other
to the first generation T-50S, current generation (T- nondestructive test methods. Increasingly, however, AE
1000) carbon fiber exhibits vast improvements with the testing alone is used to evaluate tanks and pressure ves-
apparent absence of stress rupture behavior to almost sels. For certain classes of metallic vessels, the use
100 000 h [30.73]. The Felicity effect is the probable of AE examination alone can be used to satisfy code-
basis for the AE method for remaining life estimation. mandated inspection requirements in lieu of ultrasonic
Research continues [30.59], but more work is needed. testing or radiography. After AE testing indicates the
locations of active AE sources, these are graded accord-
30.5.2 Metal Pressure Vessels, Tanks, ing to criteria similar to those for composite vessels.
and Piping These provide real-time indications of defective areas of
the pressure vessel being tested and prevent catastrophic
Acoustic emission testing of metallic tanks and pressure failure of the vessel. The identified defective areas are
vessels is conducted during pressurization. The tanks then inspected using other test methods. Acoustic emis-
and vessels are pressurized following applicable code sion testing is applied on various types of vessels,
specifications. The maximum pressure is typically up to including ammonia spheres and tanks, hydroformer re-
110% of the operating pressure. Sources of emissions actors, and catalytic cracking units [30.1, 75].
are usually crack growth, yielding, corrosion effects In condition monitoring of the bottom plates of
(cracking or spalling of corrosion product, local yield- aged petroleum tanks, experience with standard AE test
ing of thinned section), stress corrosion cracking and methods was reviewed [30.76]. These often encounter

Part H 30.5
embrittlement. The most likely locations of flaws are difficult conditions and have poor location accuracy.
at various weldments. When metals are ductile, AE ac- Lamb wave-based methods can bring the needed im-
tivities are low and AE test results should be evaluated provements, accurately positioning corroded sections.
carefully. Once the metals are embrittled by the envi- Correlations of active AE areas with thinned sections
ronment or at low temperatures, even early stages of are shown in Fig. 30.25 [30.74].
stressing activate AE sources. In fact, AE is the best
method for detecting hydrogen-induced cracking and 30.5.3 Aerospace
stress corrosion cracking [30.1].
Highway gas-trailer tubes and chemical and petro- The first application of AE testing was to verify the
chemical vessels are monitored with AE periodically structural integrity of filament-wound Polaris rocket
without the vessels being emptied, thus minimizing the motorcases in 1961 [30.65]. Hydrostatic testing of
cost of testing. According to current industrial prac- rocket motorcases was instrumented using accelerom-
1226 Part H Engineering Acoustics

eters, audio recording, and sound analysis equipment. of a mining region can also activate the areas of high
Crack initiation and propagation were detected prior to local stresses. Multichannel AE sensing has also been
catastrophic failure. Later, burst pressure was success- applied to the evaluation of hydrofracturing in geother-
fully predicted based on AE data during proof testing. mal wells [30.81]. The stability of underground storage
The composite rocket motorcases are still successfully caverns is another area of AE applications [30.5].
inspected with the use of three (or four) pressurization By using the Kaiser effect, underground stresses
cycles. The first cycle is to find leaks at a low pres- may be estimated. Compressive stresses are applied on
sure. The second goes to 100% (or 80%) of the mean a sample bored out from underground. When the previ-
expected operating pressure, followed by the third to ously existing stress is exceeded, AE activities increase
the 80% level. The AE behavior during the third cycle and the preexisting stress can be estimated. Since a high
is used to examine the Felicity effect and is the deter- compressive pressure always exists, the directionality of
mining factor in the evaluation of the rocket motorcase stresses must be taken into account. However, loading
integrity. methods and relaxation after coring may have effects
AE testing is as yet unable to monitor the integrity on the results [30.82].
of aircraft structures in flight because of the substan- AE techniques have been applied to monitoring
tial noise generated from structures that are joined the stability of highway slopes, tunnels, and landslide-
by numerous fasteners and from engines. For specific prone areas [30.2]. AE measurements utilize waveg-
components, however, AE can detect the presence of uides that are driven into the ground. By mapping high
cracks and incipient fracture. For surveillance of struc- AE activity areas, potential instability regions can be
tural and fatigue damage of aircraft components during predicted. Concrete with steel reinforcement is another
limit load and fatigue testing, AE has demonstrated its material used widely in civil engineering structures. Be-
utility. All significant cracks were located during full- cause of the large size of concrete structures and high
scale fatigue testing, including those emanating from attenuation rates of AE signals in concrete, suitable AE
bolt holes amid a wide range of spurious AE sources. techniques for structural integrity monitoring are yet to
AE in curved fuselage panes of honeycomb sandwich be perfected [30.3–6].
composites was monitored, showing the evolution of
notches and a good correlation with accumulated AE. 30.5.5 Bridges
Strong AE from fiber damage was less than 5% of
the total AE events recorded [30.77]. AE indications AE monitoring of thousands of steel bridges has been
of damage severity vary depending on the particular conducted, providing operators ample warning of po-
component, but include load hold emissions, FR, AE tential disasters [30.83, 84]. Most test sites had no
event rates, and high amplitude emissions. In structural fatigue indications, but a dozen or so had high AE ac-
tests, wave propagation characteristics and the nature tivity in a 10-year period. AE monitoring is applied
of crack-related (crack growth and crack face fretting) to selected locations, not globally to large structures.
sources are also essential in evaluating AE observa- These include: hanger connections, link pin connection,
tions. Other developments include fiber sensors capable copes and stringers, and stiffener to weld connection.
of being integrated into composite structures and ac- Loading is supplied by regular rail traffic. Other moni-
tive surveillance schemes using AE sensing for damage toring efforts are summarized in [30.85].
detection [30.78–80]. A recent example of large bridge monitoring used
Part H 30.5

600+ AE channels to monitor about 400 critical sites on


30.5.4 Geological Structures the San Francisco-Oakland Bay Bridge [30.86]. Remote
monitoring was implemented and success was achieved.
AE monitoring has been studied to promote mine safety The system will be transferred to the replacement bridge
by detecting incipient rock bursts and gas outbursts and opened in 2013 and AE monitoring will be continued.
by estimating the areas of stress concentration ahead of Many other new and old AE applications to struc-
mining regions [30.2–6]. For this purpose many AE sen- tural integrity evaluation exist, including off-shore oil
sors are placed in and around mine tunnels and monitor rigs, on-board rocket and spacecraft, continuous moni-
low frequency (below several kHz) AE signals. A min- toring of rocket motorcases, cable-stayed bridges, wind
ing operation itself can be a stimulus, as underground turbine blades, power plants, refinery, factory installa-
rocks have numerous preexisting flaws and are under tions, and gas tanks. Details are usually inaccessible, but
geological pressure. Drilling exploratory holes ahead some references are listed in [30.87–90].
Acoustic Emission References 1227

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