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Preface |
8 |
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Acknowledgments |
10 |
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Contents |
12 |
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Financial Support |
16 |
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About the Author |
18 |
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Chapter 1: Introduction |
19 |
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References |
22 |
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Chapter 2: Failure of Fiber-Reinforced Composites |
23 |
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2.1 Classification of Failure Mechanisms |
24 |
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2.1.1 Microscale |
25 |
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2.1.2 Mesoscale |
31 |
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2.1.3 Macroscale |
34 |
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2.2 Failure Theories for Fiber-Reinforced Composites |
36 |
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2.2.1 Quasi-Static Failure |
36 |
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2.2.2 Quasi-Static Failure Including Growth of Damage, Damage Mechanics, and Degradation |
39 |
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2.2.3 Long-Term Behavior |
46 |
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2.2.3.1 Creep and Stress Rupture |
46 |
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2.2.3.2 Fatigue |
48 |
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2.2.4 High Velocity |
50 |
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2.3 Challenges in Mechanical Testing of Fiber-Reinforced Materials |
51 |
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2.3.1 Detection of First Failure Onsets |
52 |
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2.3.2 Tracking Failure Evolution |
53 |
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2.3.3 Ductile Matrix Materials |
54 |
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2.4 What Can In Situ Methods Contribute to Mechanical Testing? |
54 |
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2.4.1 In Situ Microscopy |
55 |
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2.4.2 Digital Image Correlation |
55 |
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2.4.3 X-Ray Methods |
56 |
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2.4.4 Thermography |
58 |
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2.4.5 Shearography |
59 |
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2.4.6 Ultrasonic Measurements |
60 |
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2.4.7 Acoustic Emission |
61 |
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2.4.8 Electromagnetic Emission |
61 |
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References |
62 |
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Chapter 3: Digital Image Correlation |
74 |
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3.1 Principle of Operation |
75 |
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3.2 System Accuracy |
80 |
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3.2.1 Error Sources |
81 |
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3.2.1.1 Systematic Errors |
81 |
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3.2.1.2 Random Errors |
83 |
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3.2.1.3 Stereo Vision |
84 |
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3.2.2 Resolution |
84 |
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3.3 Strain Concentration |
86 |
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3.3.1 Measurement of Strain Concentration Due to Internal Defects |
88 |
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3.3.2 FEM Modeling of Strain Concentration Due to Internal Defects |
97 |
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3.3.2.1 Full-Field Comparison |
98 |
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3.3.2.2 Signatures of Artificial Defects |
104 |
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3.3.3 Detectability of Defects Using DIC |
114 |
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3.3.3.1 Experimental Parameters |
116 |
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3.3.3.2 Applicability of the Modeling Approach to Real Defects |
120 |
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3.3.3.3 Limitations Due to System Accuracy |
122 |
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3.4 Application to Composites |
128 |
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3.4.1 DIC as Optical Extensometer |
128 |
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3.4.1.1 Tensile Testing of Unidirectional Fiber Reinforced Polymers |
129 |
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3.4.1.2 Compressive Testing of Unidirectional Fiber Reinforced Polymers |
131 |
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3.4.1.3 V-Notched Rail Shear Testing of Unidirectional Fiber Reinforced Polymers |
133 |
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3.4.2 Detection of Failure Onsets |
135 |
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3.4.2.1 Short-Beam Shear Tests |
136 |
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3.4.2.2 End-Notched Flexure Tests |
138 |
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3.4.3 Detectability of Failure Mechanisms |
141 |
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References |
143 |
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Chapter 4: Acoustic Emission |
147 |
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4.1 Principle of Operation |
147 |
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4.2 Source Mechanics |
149 |
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4.2.1 AE Rise-Times and Plate Waves |
151 |
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4.2.2 AE Source Model Implementation for Fiber Reinforced Materials |
154 |
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4.2.2.1 Source Models for Microscale |
159 |
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4.2.2.2 Source Models for Meso- and Macroscale |
162 |
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4.2.3 Case Studies for Acoustic Emission Sources in Fiber Reinforced Materials |
163 |
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4.2.3.1 Inter-fiber Failure |
166 |
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Tensile Perpendicular |
167 |
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Compression Perpendicular |
172 |
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Shear Parallel |
174 |
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Bending sigman |
177 |
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4.2.3.2 Delamination |
181 |
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Shear Parallel |
183 |
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Bending sigman |
185 |
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4.2.3.3 Fiber Failure |
189 |
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Tension Parallel |
189 |
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Compression Parallel |
192 |
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4.2.3.4 Fiber Bridging |
195 |
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4.2.3.5 Influence of Crack Length |
200 |
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4.2.3.6 Influence of Fracture Surface |
201 |
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4.2.3.7 Influence of Depth Position |
202 |
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4.2.4 Detectability of Failure Mechanisms |
203 |
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4.3 Wave Propagation |
208 |
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4.3.1 Attenuation |
218 |
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4.3.1.1 Geometric Spreading |
219 |
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4.3.1.2 Thermoelastic and Akhiezer Dissipation |
219 |
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4.3.1.3 Dispersion |
220 |
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4.3.1.4 Scattering |
220 |
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4.3.1.5 Dissipation into Adjacent Media |
220 |
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4.3.1.6 Modeling Attenuation |
220 |
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4.3.2 Influence of Geometry |
222 |
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4.3.3 External and Internal Obstacles |
230 |
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4.3.3.1 Reference Case |
232 |
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4.3.3.2 Rivets and Bolts |
234 |
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4.3.3.3 Holes |
236 |
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4.3.3.4 Inter-fiber Cracks |
236 |
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4.3.3.5 Broken Fibers |
239 |
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4.3.3.6 Delamination |
240 |
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4.3.3.7 Influence on Signal Arrival Times |
241 |
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4.4 Detection of Acoustic Emission Signals |
242 |
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4.4.1 Comparison of Sensor Types |
246 |
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4.4.2 Sensor Modeling |
249 |
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4.4.2.1 Influence of Attached Circuit |
251 |
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4.4.2.2 Influence of Sensor Aperture |
253 |
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4.4.2.3 Influence of Impedance Mismatch |
254 |
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4.4.3 Waveguides |
255 |
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4.4.3.1 Shape of Waveguide |
258 |
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4.4.3.2 Diameter of Waveguide |
259 |
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4.4.3.3 Material of Waveguide |
259 |
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4.4.3.4 Influence of Temperature Gradient |
261 |
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4.4.4 Other Factors Affecting Sensor Sensitivity |
261 |
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4.4.4.1 Coupling Medium |
261 |
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4.4.4.2 Sensor Fixation |
264 |
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4.5 Signal Classification |
266 |
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4.5.1 Recommended Practices Before Starting Signal Classification |
268 |
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4.5.2 Pattern Recognition Method to Detect Natural Clusters |
272 |
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4.5.3 Uncertainty of Classification |
276 |
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4.5.4 Factors of Influence |
280 |
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4.5.4.1 Source-Sensor Distance |
281 |
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4.5.4.2 Plate Thickness |
284 |
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4.5.4.3 Stacking Sequence |
285 |
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4.5.4.4 Internal Damage |
292 |
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4.5.4.5 Sensor Type |
294 |
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4.5.4.6 Signal-to-Noise Ratio |
297 |
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4.6 Source Localization |
298 |
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4.6.1 Determination of Signal Onset |
301 |
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4.6.2 Classical Localization Methods |
303 |
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4.6.3 Source Localization Methods Based on Neural Networks |
307 |
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4.6.3.1 Training Stage Using Test Sources |
309 |
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4.6.3.2 Compensation of Acoustic Anisotropy |
314 |
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4.6.3.3 Discontinuous Deltat-Fields |
318 |
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4.6.3.4 Scale Invariance and Portability |
319 |
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4.7 Application to Composites |
321 |
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4.7.1 AE Source Identification Using FEM Results |
321 |
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4.7.2 Detection of Failure Onset |
325 |
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4.7.2.1 Apparent Interlaminar Shear Strength Tests |
325 |
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4.7.2.2 End-Notched Flexure Tests |
327 |
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4.7.2.3 Transverse Crack Tension Tests |
328 |
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4.7.3 Comparison to Failure Criteria Predictions |
333 |
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4.7.3.1 Unidirectional Laminates |
333 |
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4.7.3.2 Cross-Ply Laminates |
336 |
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4.7.4 Tracking Failure Evolution |
343 |
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4.7.4.1 Double-Cantilever Beam Testing |
343 |
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4.7.4.2 Tensile Testing |
350 |
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4.7.4.3 Structural Components |
355 |
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References |
365 |
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Chapter 5: Electromagnetic Emission |
376 |
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5.1 Principle of Operation |
376 |
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5.2 Source Mechanism |
378 |
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5.2.1 Modeling of Electromagnetic Emission Sources |
386 |
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5.2.1.1 Implementation and Validation |
387 |
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5.2.1.2 Source Radiation Pattern |
396 |
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5.2.1.3 Influence of Distance Between Source and Sensor |
398 |
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5.2.1.4 Influence of Electrical Properties |
400 |
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5.2.1.5 Sources in Fiber Reinforced Composites |
400 |
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5.2.2 Test Sources for Electromagnetic Emission |
404 |
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5.3 Signal Propagation |
411 |
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5.4 Detection of Electromagnetic Emission Signals |
415 |
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5.4.1 EME Detector Concepts |
416 |
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5.4.1.1 Capacitance Plate Sensors |
418 |
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5.4.1.2 Wire Sensors |
421 |
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5.4.1.3 Coil Sensors |
422 |
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5.4.1.4 Comparison and Common Aspects |
423 |
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Material |
426 |
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Positioning |
426 |
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Preamplifier |
427 |
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Acquisition |
427 |
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5.4.2 Electromagnetic Shielding |
428 |
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5.4.2.1 Apertures |
435 |
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5.4.2.2 Waveguides Below Cutoff |
438 |
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5.4.2.3 Seams |
440 |
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5.4.2.4 Cable Penetrations |
441 |
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5.5 Application to Composites |
442 |
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5.5.1 Measurement of EME Due to Crack Formation |
442 |
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5.5.1.1 Polymer Failure |
443 |
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5.5.1.2 Fiber Filament Failure |
448 |
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5.5.1.3 Composites |
451 |
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5.5.2 Measurement of Fracture Surface Orientation |
460 |
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5.5.3 Detectability of Failure Mechanisms |
465 |
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5.5.3.1 Absolute System Limits |
465 |
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5.5.3.2 Signal-to-Noise Ratio |
466 |
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5.5.3.3 Acquisition Mode |
467 |
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References |
468 |
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Chapter 6: Computed Tomography |
472 |
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6.1 Principle of Operation |
473 |
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6.2 Detail Visibility |
476 |
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6.2.1 Object Resolution |
477 |
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6.2.2 Artifacts |
479 |
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6.2.2.1 Physics-Based Artifacts |
481 |
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Beam Hardening |
481 |
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Cupping Artifact |
481 |
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Dark Bands |
482 |
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High-Density Foreign Material Artifact |
482 |
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Partial Volume Averaging |
483 |
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Quantum Mottle (Noise) |
484 |
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Photon Starvation |
486 |
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Undersampling |
486 |
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6.2.2.2 Hardware-Based Artifacts |
487 |
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Ring Artifact |
487 |
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Tube Arcing |
487 |
|
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6.2.2.3 Reconstruction Artifacts |
488 |
|
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Cone-Beam Effect |
488 |
|
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Windmill Artifacts |
488 |
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6.2.2.4 Motion Artifacts |
489 |
|
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6.2.3 Detectability of Defects in Fiber Reinforced Materials |
490 |
|
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6.3 Volumetric Inspection of Materials |
496 |
|
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6.3.1 Concepts for Ex Situ Loading |
496 |
|
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6.3.2 Concepts for In Situ Loading |
497 |
|
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6.3.2.1 Type of X-ray Source |
498 |
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6.3.2.2 Type of X-ray Detector |
499 |
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6.3.2.3 Type of Load Rig |
499 |
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Tensile or Compressive Load Test |
501 |
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Mode I Test |
504 |
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Flexural Test and Mode II Test |
505 |
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Thermal Loading |
506 |
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Imaging Requirements |
507 |
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6.4 Digital Volume Correlation |
508 |
|
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6.5 Application to Composites |
513 |
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6.5.1 Ex Situ Testing |
517 |
|
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6.5.1.1 Visualization of Damage Progress |
517 |
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6.5.1.2 Extraction of Geometries from Volume Data |
521 |
|
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6.5.2 In Situ Testing |
530 |
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6.5.2.1 Inter-fiber Failure |
533 |
|
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6.5.2.2 Fiber Failure |
535 |
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6.5.2.3 Interlaminar Failure |
540 |
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References |
542 |
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Chapter 7: Combination of Methods |
548 |
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7.1 Comparison of In Situ Methods |
549 |
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7.1.1 In Situ Capabilities |
551 |
|
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7.1.2 Detectability of Failure Mechanisms |
553 |
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7.1.3 Detection Sensitivity |
555 |
|
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7.1.4 Extension of Methods to Large Scale and Field Testing |
558 |
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7.2 Established Method Combinations |
563 |
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7.2.1 Imaging Methods and Acoustic Emission |
563 |
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7.2.2 Digital Image Correlation and Acoustic Emission |
570 |
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7.2.3 Thermography and Acoustic Emission |
573 |
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7.2.4 Computed Tomography and Acoustic Emission |
578 |
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7.2.4.1 Ex Situ Computed Tomography |
578 |
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7.2.4.2 In Situ Computed Tomography |
588 |
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Inter-Fiber Failure |
593 |
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Fiber Failure |
602 |
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7.2.5 Computed Tomography and Digital Image Correlation |
605 |
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7.2.6 Electromagnetic Emission and Acoustic Emission |
605 |
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7.2.7 Acousto-Ultrasonics |
611 |
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7.3 Future Developments |
616 |
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7.3.1 Digital Image Correlation |
617 |
|
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7.3.2 Acoustic Emission |
617 |
|
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7.3.3 Electromagnetic Emission |
619 |
|
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7.3.4 In Situ Computed Tomography |
620 |
|
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7.3.5 Method Combinations |
621 |
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References |
621 |
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Appendix A: Acoustic Emission-Parameters of Influence |
625 |
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A.1 Acquisition System Electronics |
625 |
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A.2 Sensing Technology |
626 |
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A.3 Material and Geometry |
627 |
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A.4 Experimental Configuration |
629 |
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Appendix B: Material Properties |
631 |
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Appendix C: Acoustic Emission Signal Parameters |
635 |
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Appendix D: Definitions and Abbreviations |
639 |
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Index |
643 |
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