ME-3200

Case Study in Mechanical Engineering

CASE STUDY PRESENATION ON

Ultrasonic Detection of Fatigue Crack Initiation

Supervised by Presented by
Dr. Md. Nurul Islam Name: Md Emamul Gazi
Professor Student ID: 1802142
Department Of Mechanical Engineering
Name: Sadia Haque Tania
Rajshahi University Of Engineering And
Student ID: 1802152
Technology

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 Outline
• Introduction
• Objectives
• Literature Review
• Proposed Methodology
• Conclusions
• Future Work Timeline
• References

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1. Introduction:
1.1.1 Motivation

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1. Introduction:

1.1.2 Problem Statement:

1. Fatigue is one of the primary reasons for the failure of structural

components.

2. Caused by simultaneous action of cyclic stress, tensile stress and plastic

strain.

3. Fatigue cracks reduces the strength and life time of components leading to
a catastrophic damage.

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1.Introduction

1.1.3 How to solve this problem?

There are several methods to determine crack initiation on a metal surface such as
Visual inspection, Liquid penetrant testing, Magnetic particle inspection,
Ultrasonic testing, Fatigue testing etc.

Ultrasonic detection of fatigue crack initiation is to develop a reliable and accurate

non-destructive testing (NDT) technique for detecting the onset of fatigue cracks
in metallic components.

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1. Introduction:

1.1.4 Why are we interested to solve the problem?

• As fatigue cracks can grow over time and lead to structural failure, it is crucial
to detect them as early as possible. This is where ultrasonic testing for fatigue
crack detection comes into play.

• It can accurately detect and locate the initiation of fatigue cracks in a wide
range of materials including ceramic, composite and metallic components
(particularly in high-stress regions such as near welded joints or bolt holes)
 

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2. Objectives:

• To evaluate the effectiveness of ultrasonic detection in detecting fatigue crack

initiation in metal components.

• To compare the traditional visual inspection method with the ultrasonic

detection method in terms of sensitivity and accuracy.

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3. Literature Review:

Title Method used Findings Limitations/

Author, Year Future work

(1) Novel Method AE method with Beneficial for early Scarcely applied to
for in situ damage the assessment of crack detection and USFT because of
monitoring during USFT device. monitoring fatigue severe noise of the
ultrasonic fatigue damage. instrumental set up
testing by the &
advanced acoustic Interfere strongly
emission technique with AE frequency
response.
(M. Seleznev,2021)

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3. Literature Review:
(2) Monitoring damage Non-Linear Nonlinear ultrasonic Initial drop in the
in composite plates Technique parameter monitor the TOF plot due to
from crack initiation to (Sideband peak early stage better while delamination.
macro crack count SPC) linear ultrasonic &
propagation combining Linear parameter are more For an existing
linear and nonlinear Technique effective for the advanced internal defects the
ultrasonic technique (Time of flight stage of damage. wavelengths of
(Hamad TOF) NLU should be
Alnuaimi,2020) much smaller.

(3) Enhanced sizing for Based on Improve the accuracy of To ensure accurate
surface cracks in Ultrasonic wave ultrasonic measurement and complete crack
welded tubular joints reflections with crack sizing sizing suggests
using ultrasonic phased capturing & different ultrasonic
array and image multiple S- scan Real time crack monitoring probe locations.
processing ultrasonic during low cycle fatigue
( Liuyang Feng, 2020) images test

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3. Literature Review:
(4) A review of non- Optical microscopy Recent Difficulties in
destructive testing (OM), X-Ray developments in implementation of
techniques for the Radiography (XR), non- destructive these techniques.
in-situ investigation Ultrasound, techniques
of fretting fatigue Thermography, applicable to fretting
cracks Acoustic emission fatigue.
(Y. Kong, C.J. (AE) and SEM
Bennett,2020) techniques.

(5) Evaluation of Based on the low cycle fatigue Predict the

start of crack growth attenuation of crack initiation on remaining life only
of nuclear material ultrasonic back surface is observed within the plastic
(SUS316NG) reflection intensity and compared the strain range.
using ultrasonic due to the change of back-
(Md. Nurul dislocation damping. reflection intensity
Islam,2013) of ultrasonic wave.

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 Research Gap:

• Many researchers have studied and investigated the on Acoustic Emission

method to distinguish between surface and internal fatigue crack initiation
and monitoring the damage in composite plates from crack initiation to macro
crack propagation by using Linear and Nonlinear ultrasonic technique.

• To detect surface crack initiation It would be better to use Ultrasonic testing

because of its ability to versatile materials with a great accuracy. Moreover
this procedure is simple and quick.

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4. Proposed Methodology:

4.1 Tentative Process Flow Diagram

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4. Proposed Methodology:

4.2 Required Instruments

• A specimen ( A Flat Bar)

• Fatigue Testing Machine
• EPOCH 650 – Ultrasonic Flaw Detector
• Metallurgical Microscope

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5. Conclusions:

The ultrasonic detection is a highly effective method for detecting

fatigue crack initiation in metal components. It provides a more
sensitive and accurate method of detecting fatigue cracks
compared to the traditional visual inspection method. This makes
ultrasonic detection a valuable tool for ensuring the structural
Integrity of industrial components and preventing catastrophic
failures. Ultrasonic detection represents a breakthrough in terms of
cost, size and high reliability under critical inspection conditions.

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5. Future Work Time Line :

The following activities are planned for putting our ideas into
action:
Task details Start date Days to complete
 
(1)Methodology 23 February 25 days
development
(2) Experimental set up 14 March 10 days

(3) Trial run 30 April 15 days

(4) Data visualization 14 May 20 days

through graph

(5) Report Writing 4 June 25 days

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 5. Future Work Time Line:
Strategy implementation and timeframe for our future work and studies are shown
below by the gantt chart.

4th year Odd Semester (weeks)

Tasks
1 2 3 4 5 6 7 8 9 10 11 12
Methodology development
Experimental set up
Trial run
Data visualization through
graph
Report writing

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 6. References:
[1] “What is a crack initiation? - definition from Corrosionpedia,” Corrosionpedia. [Online]. Available:
https://www.corrosionpedia.com/definition/6397/crack-initiation#:~:text=Crack%20initiation%20is
%20a%20process,any%20material%20experiences%20cyclic%20loading. [Accessed: 18-Feb-2023].

[2] “There are cracks and flaws in a metallic component used in construction of buildings. explain how
it can be detected? [3 marks],” byju. [Online]. Available: https://byjus.com/question-answer/there-are-
cracks-and-flaws-in-a-metallic-component-used-in-construction-of-buildings-explain-1/. [Accessed: 18-
Feb-2023].

[3] /* inline tdc_css att */.tdi_88{margin-right:10px !important;}/* custom css */.tdb-post-meta{

margin-bottom: 16px; color: #444; font-family: 'Open Sans', Constro Facilitator, By,
Constro Facilitator, J. 22, F. 9, D. 30, M. 5, S. 26, J. 8, J. 24, F. 13, F. 14, and F. 16, “What is the history of
ultrasonic testing?,” Constro Facilitator, 12-Apr-2022. [Online]. Available:
https://constrofacilitator.com/what-is-the-history-of-ultrasonic-testing/. [Accessed: 18-Feb-2023].

[4] Early history of metal flaw detectors. [Online]. Available: https://www.ob-

ultrasound.net/ndt.html. [Accessed: 18-Feb-2023].

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6. References:
[5] “What is ultrasonic testing and how does it work?,” TWI. [Online]. Available: https://www.twi-
global.com/technical-knowledge/faqs/ultrasonic-testing#:~:text=Periodic%20ultrasonic
%20inspections%20can%20also,medical%2C%20metallurgy%2C%20and%20manufacturing. [Accessed:
18-Feb-2023].

[6] Author links open overlay panelY. Kong, Highlights•A review on recent non-destructive techniques
that have been used in-situ with fretting fatigue tests for crack detection.•Comparisons of the
sensitivity, and AbstractFretting fatigue can significantly reduce the life of components, “A review of
non-destructive testing techniques for the in-situ investigation of fretting fatigue cracks,” Materials
& Design, 29-Aug-2020. [Online]. Available:
https://www.sciencedirect.com/science/article/pii/S0264127520306286. [Accessed: 18-Feb-2023].

[7] M. N. Islam, A. Yoshio, and A. Wakako, “Evaluation of start of crack growth of nuclear material
(SUS316NG) using ultrasonic,” Procedia Engineering, vol. 56, pp. 707–712, 2013.

[8] I. M. Nurul, Y. Arai, and W. Araki, “Initiation of fatigue crack growth in austenitic stainless steel
detected by ultrasound: Role of in-plane orientation,” Materials Science and Engineering: A, vol. 556,
pp. 309–318, 2012.

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 6. References:
[9] M. Seleznev, A. Weidner, H. Biermann, and A. Vinogradov, “Novel method for in situ
damage monitoring during ultrasonic fatigue testing by the advanced acoustic emission
technique,” International Journal of Fatigue, vol. 142, p. 105918, 2021.

[10] H. Alnuaimi, U. Amjad, P. Russo, V. Lopresto, and T. Kundu, “Monitoring damage in

composite plates from crack initiation to macro-crack propagation combining linear and
nonlinear ultrasonic techniques,” Structural Health Monitoring, vol. 20, no. 1, pp. 139–
150, 2020.

[11] M. N. Islam, A. Yoshio, and A. Wakako, “Evaluation of start of crack growth of

nuclear material (SUS316NG) using ultrasonic,” Procedia Engineering, vol. 56, pp. 707–
712, 2013.

[12] O. IMS, “Olympus IMS,” Olympus Inspection Solutions-NDT, Microscopes, XRF, RVI,
09-Jan-2017. [Online]. Available: https://www.olympus-ims.com/en/advancements-in-
offshore-corrosion-monitoring-and-flaw-detection/. [Accessed: 18-Feb-2023]

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