non-destructive testing for light-weighting of automobile ... · • ultimate tensile strength, rm...
TRANSCRIPT
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Non-destructive Testing forLight-weighting
of Automobile Components
ACMA – Fraunhofer Technology Day on
Resource Efficiency in Car Manufacturing
New Delhi, September 8th 2011
Sven Kurzenhäuser
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• Introduction: Fraunhofer IZFP
• Application examples of NdT solutions for
• metal working industries
• joining processes
• Summary and conclusions
Contents
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Employees
130 Scientists and engineers
12 Technicians & 29 supportingpersonnel
140 PhD and Diploma students, Research assistantsGuest Scientists
Finances
25.9 Mio € from which
13.8 Mio € by orders from industry
Institute for Non-destructive Testing IZFP at a Glance
Methods and Techniques
Ultrasonic, Eddy Current, Electromagnetics, Micromagnetics, Microwave, x-ray-Radio-scopie, Tomo-, Laminography, Atomic-Force-Mikroscopy, Thermography, Acoustic Emission, Nuclear Magnetic Resonance
Saarbrücken Dresden
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Materials
Components& parts
Manufacturing & joining processes
Quality
AQS - The innovation cluster Automotive Quality Saar
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Metal working
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IZFP Solutions for the Automotive and Supplier Industry
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Testing of heavy steel plates
Fully-automated inline ultrasonic and micromagnetic testing
� 100% testing of the plate volume since 1998
� 1 m/s production line speed
� Plate thickness 6-60 mm
� Average productivity was 60 000 tons/month
� Detection of faults from 2 mm diameter on
� Detection of „cold ends“ by their anomalous mechanical properties reduces pseudo-scrap
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3D-SAFT reconstructed image
0,3-10 MHz
Dynamic 100 dB
12 bit resolution
Line speed 100mm/s
Reconstruction volume 230×135×65 mm3
0,3 mm step size
5 Min (134 MByte)
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Testing of heavy steel plates
Fully-automated inline ultrasonic testing
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Detection of pores in Aluminum components
by high-frequency ultrasonic reflection
Detection of subsurface pores and other inclusions by ultrasonic backscattering (above) or high frequency eddy current or thermography
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Ultrasonic systems to evaluate the hardening depth
Evaluation of surface hardening depthby ultrasonic reflection
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Wedge
Coupling (e.g. oil)
Induction hardened layer
Received surface echo
Scattered waves
Received signal of averagedscattered signals
Base material
Ultrasonic Probe
Evaluation of surface hardening depthby ultrasonic reflection - principle
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3MA sensor
Semi-automated system
3MA system
Mechanical properties as hardness, case depth, yield strength, residual or load stress state are correlated to the micromagnetic and electromagnetic material properties, measured by the 3MA system
Evaluation of grinding burns, hardness, internal stresses
... and other quantitative material properties after calibration
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Demands of automotive industry
…increased fuel efficency by lightweightdesign.
… improved chassis stiffness andcrash performance.
High strength steels by press hardening
... enabling superior, tailored properties
High strength steels
Car body and frame requests high
strength boron-manganese steels:
Yield Strength, Hardness, Toughness, Stress State, Homogeneity, Defect Detection, …
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Replacement of destructive testingby non-destructive testing of• Hardness• Yield strength, Rp0.2• Ultimate tensile strength, Rm• Elongation, A50with the 3MA technique and
tool-integrated sensors
Invest: ~ 100 T€
Return of invest in 7 months(for a medium production line)
Online process control during press hardening
... enabling superior, tailored properties of high strength steels
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Characterization of deep drawing processes
by micromagnetics
0.05
0.07
0.09
0.11
0.13
45 50 55 60 65
Stamp path [mm]
ND
T q
uantity
(M
max [V
])
190 kN
230 kN
270 kN
295 kN
320 kN
Stamp force:
Blank break� Tool stamp with integrated 3MA sensor
� In-situ evaluation of material properties
� In-situ evaluation of external and internal stress
� Allows precise control of stamp forces
�Avoids cracks and inhomogenious thickness /necking
Deep drawing machine with integrated sensor
Sensor
Miniaturised3MA sensor
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Active thermography - a flexible NdT solution
...allowing cost-efficent mass testing of parts with various geometries
First certification of active thermography in
Europe, enabling replacement of penetration
testing – i.e. for forged, casted or hardened parts
DIN EN ISO / IEC 17025 : 2005
DAP-PL-3482.00
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3D reconstr. of 100 angle scans (25 s)3D reconstr. of 400 angle scans (100 s)
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High resolution customer specific x-ray systems
Image analysis and evaluation by improved reconstruction algorithms
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� 2-D image analysis
� Automated evaluation
� Mixed mode
� Fully integrated in the production line
� Feedback-loop allows fully automated adjustment ofcasting parameters
� 100% testing anddocumentation of parts quality
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X-ray with automated 2D image reconstruction
ISAR - Intelligent System for Automated Radiography
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Joining processes
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IZFP Solutions for the Automotive and Supplier Industry
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The simultaneous presentation of ultrasonic time-of-flight (green) and the applied torque yields a redundant clamp load evaluation, independent of friction influences
Evaluation of clamp load for process control
Assessment of the clamp load directly at the screw thread
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LASUS systemAutomated ultrasonic system using EMAT (EEEElectroMMMMagnetic Acoustic TTTTransducers) to inspect the laser welds of tailored
blanks
Testing of laser-welded tailored steel (and Al) blanks
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Transducer
X-ray result LASUS result
strong porosity - laser power too high
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The undercut determines the quality of the clinch joint.The total wall thickness is a direct measure for the material, pressed into the undercut area.
Undercut
Wall Thickness
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Characterization of clinch strength
by ultrasonic transmission
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Parts of a door beam
-134°
-109°
Active thermography, Pulse-Phase-Contrast at 3.5 Hz
Joining line
Indications: to much adhesive applied (left hand side), insufficent line width(center), delamination (right hand side)
Characterization of adhesive joining processes
Enabling material efficency and improved properties
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Summary & Conclusions
Conclusions:
� Demands for higher parts quality and lower costs are not necesarily in contrast
� Process orientation in combination with sophisticated NdT solutions give insight inprocesses and enable innovation
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Summary:
� Various NdT techniques are employed in automotive industry for quality acessment and documentation of product quality
� Increasing demand for in-line NdT systems, not only for defect detection but for acessment of quantitative material properties
� Evaluation of process induced changes of material properties allows control and optimization of manufacturing processes
� By that, an increased resource efficency, light-weighting of parts as well as superior product quality are enabled
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Fraunhofer Institute for Non-destructive Testing IZFP
„… we can supply insight…“
© Nick Veasey
Thank you for your attention!
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Evaluation of position and sealing function of adhesive bond seams ofcrimped door beams
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Characterization of adhesive joining processes
Enabling material efficency and improved properties
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Multy frequency eddy current system enables the off-line characterization of the final wall thickness of the clinch joint.
0,55
0,60
0,65
0,70
0,75
0,80
0,85
0,90
0,95
0 10 20 30 40 50 60 70 80 90 100 110 120 130
Clinchpunkt
Bodendic
ke [m
m]
Streuung mech. Messwerte: 0,02 mm±
Validation by comparison with results of destructive technique
Characterization of Strength and Process Control IZFP Solutions
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optisches Bild
Millimeterwellenbild, zweidimensionalerScan, 94 GHz-Radar, 120 × 120 mm²
Detektion von Bereichen mit fehlerhafter Faserverteilung an einer Blattfeder aus glasfaserverstärktem Kunststoff (Radaufhängung von Kleinlastern)
Defektdetektion in Glasfaserverbundmaterial
GFK-Blattfeder(Benteler)
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IZFP
Testing of CFRP componentes with Sampling PhasedArray UltrasonicsIZFP Solution
� Detection of production faults
� Characterisation of material damages resulting from impacts
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Conventional PA and Sampling PA-Reconstruction
•Inspection of Composites
•Faster inspection speed
•Pitch-catch mode so less dead zone
•SAFT(Synthetic Aperture Focussing Technique)reconstruction
L
2
x
L
Rückwand
F1F2
F4
Sektorbild
L
2
x
L
F3
Rückwand
F1F2
F4
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Prüfung vonHochleistungskeramiken, Schäume, Polymerverbunde
Luft-Ultraschall: Berührungslose Qualitätssicherung neuer Werkstoffe
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0.05
0.07
0.09
0.11
0.13
45 50 55 60 65
Stamp path [mm]
ND
T q
uantity
(M
max [V
])
190 kN
230 kN
270 kN
295 kN
320 kN
Stamp force:
Blank break
MagnetikTiefzieh-Regelung
� 3MA-Sensor ist in den Tiefziehstempel integriert
� In-situ Bestimmung der Werkstoffeigenschaften
� In-situ Bestimmung von Eigen-, Lastspannungen
� Regelung (Stempel- Niederhaltekraft, etc.)
�Vermeidung von Rissen, Einschnürungen
Sensor im Stempel einer Tiefziehpresse
Sensor
Miniaturisierter3MA-Sensor
Kernkompetenz
P ü brozess berwachung und - eherrschung
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Characterisation of CFRP components by multi-frequency eddy current testing
� Testing frequencies 10Hz – 10MHz, multi-frequency mode by time multiplexing� Directional probes give precise information on squints, missing rovings (1,5,6),suspensions/reverse faults, fraying, fussy balls, extraneus material (3 – test fault), ondulations (4)as well as delaminations (2) in Rohgelegen and CFRPs.
21 3
4 5 6
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Scanwinkel 12°Testfehler: Bohrung ∅ 3 mm
Sampling Phased Array
KonventionellesPhased Array
Ultraschalltechniken
Untersuchung eines CFK-Prüflings
Methoden
Ultraschall
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On-line evaluation of wall thickness using ultrasonic technique
Blech-Al-LegierungStahlblech
0 20 40 60 80 100 120 140 160 180 200
Prozesszeit [ms]
1,2
1
0,8
0,6
0,4
0,2
0
Ble
chdic
ke [m
m]
Thi
ckne
ss
Process Time
Characterization of Strength and Process Control IZFP Solutions
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MikrowelleGas Assisted Injection Molding (GIT)
� Korrekte Abfolge der Prozessschritte und korrekte Position der Gasblase innerhalb des Hohlkörpers
� Lösung: Miniaturisiertes GIT Überwachungssystem auf Basis eines 94 GHz Radarsensors
� Aufzeichnung der Mikrowellen-Amplitude, -Phase und Frequenz
�Charakteristische Signaländerungen für jeden Prozessschritt
�Detaillierte Prozessüberwachung
Layout der GIT-Prozess-überwachung mit Radarsensor
Charakteristische Signaländerungender einzelnen Prozessschritte
MiniaturisiertesRadarmodul
Kernkompetenz
P ü brozess berwachung und - eherrschung
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© Nick Veasey
Fraunhofer Institut für Zerstörungsfreie Prüfverfahren IZFP
„… we can supply insight…“
Thank you for your attention!
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