Accessible Requires Authentication Published by De Gruyter May 26, 2013

Upgrading of an Ultrasonic Fatigue Testing Machine by Means of Early Stage Damage Detection

Erweiterung eines Ultraschall-Ermüdungsprüfsystems durch frühe Schädigungserkennung
Stephan Kovacs, Sebastian Stille, Daniel Ernstes and Tilmann Beck
From the journal Materials Testing


This contribution highlights the implementation of different methods for early stage damage detection in very high cycle fatigue (VHCF) experiments by means of an ultrasonic testing machine developed by BOKU in Vienna. Basically three different methods are used for in-situ evaluation of degradation: the analysis of (i) the harmonics, (ii) the development of the resonance frequency, (iii) the damping behaviour of the specimen at the end of each testing pulse. The fatigue experiments and measurements of the relevant parameters are controlled using the software LabView. We demonstrate the sensivity of the different methods on two specimen variants: (i) round samples of the chromium steel X10CrNiMoV12-2-2 and (ii) flat samples of the aluminium alloy Al-2024.


Dieser Beitrag beschreibt die Implementierung verschiedener Methoden zur frühzeitigen Schädigungsdetektion bei Ultraschall-Ermüdungsversuchen im Bereich sehr hoher Lastspielzahlen (VHCF) durch den Einsatz von Ultraschall-Prüfsysteme, die von BOKU (Wien) entwickelt wurden. Zur in-situ Bewertung der Ermüdungsschädigung werden drei Methoden angewandt: (i) eine Oberwellenanalyse der Probenbeanspruchung, (ii) die Entwicklung der Resonanzfrequenz über der Zykluszahl, (iii) das Dämpfungsverhalten der Proben am Ende jedes Prüfimpulses. Die Ermüdungsversuche sowie die Messungen der relevanten Parameter werden mithilfe der Software LabView gesteuert und ausgewertet. Die Sensitivität der drei untersuchten Methoden wird exemplarisch an zwei technisch relevanten Probensystemen: (i) Rundproben des Chromstahls X10CrNiMoV12-2-2, sowie (ii) Al-2024 Flachproben dargestellt.

Stephan Kovacs was born in 1983 in Aachen, Germany. After studying material science at the RWTH Aachen, Germany, he works at the Institute of Energy and Climate Research (IEK) of the Forschungszentrum Jülich, Germany, as PhD student since August 2010 in the department of Microstructure and Properties of Materials (IEK-2) with the focus on very high cycle fatigue (VHCF).

Sebastian Stille was born in 1984 in Dinslaken, Germany. He studied physics at RWTH Aachen University, Germany, as well as material and nano-science at UPMC Paris VI, France. Since 2012 he works as PhD student at the Institute of Energy and Climate Research IEK-2 at Forschungszentrum Jülich, Germany. His work lies in the field of very high cycle fatigue of materials.

Daniel Ernstes was born in 1985 in Aachen, Germany. He studied engineering specializing in aviation at RWTH Aachen University, Germany. During his studies he participated in a research project about detecting early stage damage in very high cycle fatigue experiments. After several contracts with Airbus Operations GmbH in research and technology departments during studies, he started working for a supplier of Airbus in Hamburg, Germany, in November 2012 focusing on development of new aircraft equipment.

Tilmann Beck, born 1967, studied mechanical engineering at Universität Karlsruhe, Germany, from 1989 to 1995. With a research work on isothermal thermomechanical fatigue of fiber-reinforced aluminum alloys, he received his Dr.-Ing. degree in 1999. From 1999 to 2006 he was head of the Near Service Loadings Lab at the Institute of Materials Science and Engineering of Universität Karlsruhe, Germany. 2007 he joined the Institute of Energy and Climate Research IEK-2 at Forschungszentrum Jülich, Germany, as head of the department “metallic structural materials”. Since 2008 he is professor of High Temperature Materials Mechanics at RWTH Aachen University, Germany, and since 2011 head of the Materials Mechanics section of IEK-2.


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Published Online: 2013-05-26
Published in Print: 2013-02-01

© 2013, Carl Hanser Verlag, München