This thesis deals with the theoretical and practical part of the phenomenon of acoustic emission. The thesis examined the theoretical foundations of this phenomenon and also described the equipment that was used in the laboratory of VUT in Brno to perform measurements. Then measurements and their analysis were described. Several possible errors that occurred during the work on the thesis were also described. Error description is the basis for error-free laboratory testing and for improving the quality of laboratory testing.

This Master’s thesis is concerned with project and construction of several versions of mounting device for verification of acoustic emission sensors parameters, selection of optimal solution and its testing. In addition is described the measurement procedure, that allows detailed analysis and evaluation of the data focused on comparing of parameters of acoustic emission sensors.

As a nondestructive examination, the acoustic emission technique is used to detect the presence of discontinuities inside of pressurized components. However, doubts still exist concerning the loading procedure to accomplish the acoustic emission testing, especially, in a pressure vessel where a uniform pressure can produce a nonuniform stress distribution due to the presence of the singularities such as the nozzles and supports. The combined loading of vapor and hydrostatic pressure can also generate a nonuniform stress distribution throughout the pressure vessel. According to the Kaiser effect, a structure with a nonuniform stress distribution should have a different acoustic emission testing result when compared to a structure with a uniform stress distribution. In this present study, the necessity to perform a stress analysis prior to the acoustic emission testing is examined. Furthermore, for the purpose of the stress analysis, two approaches are discussed, the membrane stress analysis and the finite element approach. By means of the membrane stress analysis, it is shown that the combined loading of the hydrostatic and vapor pressure does not produce a significant variation of stress throughout the spherical vessel. Actually, a computer program based on the membrane stress analysis is written to determine the stress distribution due to the combined loading. The limitation of the membrane stress analysis to handle problem with the presence of bending stress is also indicated. The finite element approach is used to perform the stress analysis of the singularities where the bending stress is important. The finite element computer program ABAQUS is used to perform the finite element stress analysis, and the mechanical computer-aided engineering program PATRAN is also used to construct the finite element model and to interpret the stress analysis results. The convenience and the success of these computer programs to handle this kind of problem are confirmed. The application of different types of finite elements to perform the stress analysis is also discussed. Results from the experiments performed by Gill, Catching and Paine [9] to measure the stress distribution of a pad reinforced nozzle is used as a benchmark to determine the performance of these finite elements. As a consequence, concrete recommendations concerning the selections of the finite elements and the stress analysis procedure are given. Finally, the influence of the stress distribution throughout the spherical pressure vessel on the acoustic emission is discussed, and the actual interpretation of the acoustic emission testing results based on the level of activity of acoustic emission without considering the nonuniform stress distribution throughout the structure is questioned. / Master of Science

Slug velocity measurement and flow regime recognition using acoustic emission technology are presented. Two non-intrusive and three intrusive methods were employed to detect the slug regime and measure its velocity using AE sensors. For the non-intrusive methods, AE sensors were placed directly on the exterior of the steel pipe section of the test rig with and without clamps. The intrusive method involved using different waveguide configurations with the AE sensors flush with the inner wall of the pipe. The experimental study presented investigated the application of Acoustic Emission (AE) technology for detecting slug velocity in addition to differentiating flow regime in two-phase (gas/liquid) flow in horizontal pipes. It is concluded that the slug velocity can be determined with acoustic emission (AE) sensors. The results were compared to slug velocities measured using high speed camera (HSC) and Ultrasound Transit Time (UST) techniques with good agreement between the three techniques at low gas void fraction (GVF). However, at high GVF (up to 95%) where the UST technique has limitations in application, the AE and HSC offered a good agreement. Flow regimes were also differentiated by using a combination of AE technology and Kolmogorov–Smirnov test technique. Stratified, slug and bubble regimes were recognised differentiated.

Acoustic emission (AE) is one of many available technologies for condition health monitoring and diagnosis of rotating machines such as bearings. In recent years there have been many developments in the use of Acoustic Emission technology (AET) and its analysis for monitoring the condition of rotating machinery whilst in operation, particularly on high speed machinery. Unlike conventional technologies such as oil analysis, motor current signature analysis (MCSA) and vibration analysis, AET has been introduced due to its increased sensitivity in detecting the earliest stages of loss of mechanical integrity. This research presents an experimental investigation that is aimed at developing a mathematical model and experimentally validating the influence of operational variables such as film thickness, rotational speed, load, power loss, and shear stress for variations of load and speed conditions, on generation of acoustic emission in a hydrodynamic bearing. It is concluded that the power losses of the bearing are directly correlated with acoustic emission levels. With exponential law, an equation is proposed to predict power losses with reasonable accuracy from an AE signal. This experimental investigation conducted a comparative study between AE and Vibration to diagnose the rubbing at high rotational speeds in the hydrodynamic bearing. As it is the first known attempt in rotating machines. It has been concluded, that AE parameters such as amplitude, can perform as a reliable and sensitive tool for the early detection of rubbing between surfaces of a hydrodynamic bearing and high speed shaft. The application of vibration (PeakVue) analysis was introduced and compared with demodulation. The results observed from the demodulation and PeakVue techniques were similar in the rubbing simulation test. In fact, some defects on hydrodynamic bearings would not have been seen in a timely manner without the PeakVue analysis. In addition, the application of advanced signal processing and statistical methods was established to extract useful diagnostic features from the acquired AE signals in both time and frequency domain. It was also concluded that the use of different signal processing methods is often necessary to achieve meaningful diagnostic information from the signals. The outcome would largely contribute to the development of effective intelligent condition monitoring systems which can significantly reduce the cost of plant maintenance. To implement these main objectives, the Sutton test rig was modified to assess the capability of AET and vibration analysis as an effective tool for the detection of incipient defects within high speed machine components (e.g. shafts and hydrodynamic bearings). The first chapter of this thesis is an introduction to this research and briefly explains motivation and the theoretical background supporting this research. The second and third chapters, summarise the relevant literature to establish the current level of knowledge of hydrodynamic bearings and acoustic emission, respectively. Chapter 4 describes methodologies and the experimental arrangements utilized for this investigation. Chapter 5 discusses different NDT diagnosis. Chapter 6 reports on an experimental investigation applied to validate the relationship between AET on operational rotating machines, such as film thickness, speed, load, power loss, and shear stress. Chapter 7 details an investigation which compares the applicability of AE and vibration technologies in monitoring a rubbing simulation on a hydrodynamic bearing.

Bubble and cavitation effects phenomena can be encountered in two-phase gas-liquid systems in industry. In certain industries, particularly high-risk systems such as a nuclear reactor/plant, the detection of bubble dynamics, and the monitoring and measurement of their characteristics are necessary in controlling temperature. While in the petro-chemical engineering industry, such as oil transportation pipelines, the detection and monitoring of bubbles/cavitation phenomena are necessary to minimise surface erosion in fluid carrying components or downstream facilities. The high sensitivity of Acoustic Emission (AE) technology is feasible for the detection and monitoring of bubble phenomena in a two phase gas-liquid system and is practical for application within the industry. Underwater measurement of bubble oscillations has been widely studied using hydrophones and employing acoustic techniques in the audible range. However, the application of Acoustic Emission (AE) technology to monitor bubble size has hitherto not been attempted. This thesis presents an experimental investigation aimed at exploring AEs from gas bubble formation, motion and destruction. AE in this particular investigation covers the frequency range of between 100 kHz to 1000 kHz. The AE waveform analysis showed that the AE parameter from single bubble inception and burst events, i.e. AE amplitude, AE duration and AE energy, increased with the increase of bubble size and liquid viscosity. This finding significantly extends the potential use of AE technology for detecting the presence of bubbles in two-phase flow. It is concluded that bubble activity can be detected and monitored by AE technology both intrusively and non-intrusively. Furthermore, the bubble size can be determined by measurement of the AE and this forms the significant contribution of this thesis.

Rotating machinery is a critical asset of industrial plants worldwide. Bearings and gearboxes are two of the most common components found in rotating machinery of industrial plants. The malfunction of bearings and gearboxes lead the machine to fail and often these failures occur catastrophically leading to personnel injuries. Therefore it is of high importance to identify the deterioration at an early stage. Among the techniques applied to detect damage in rotating machinery, acoustic emission has been a prevalent field of research for its potential to detect defects at an earlier stage than other more established techniques such as vibration analysis and oil analysis. However, to reliably detect the fault at an early stage de-noising techniques often must be applied to reduce the AE noise generated by neighbouring components and normal component operation. For this purpose a novel signal processing algorithm has been developed combining Wavelet Packets as a pre-processor, Hilbert Transform, Autocorrelation function and Fast Fourier transform. The combination of these techniques allows identification of g repetitive patterns in the AE signal that are attributable to bearing and gear damage. The enhancement for early stage defect detection in bearings and gears provided by this method is beneficial in planning maintenance in advance, reducing machinery down-time and consequently reducing the costs associated with bearing breakdown. The effectiveness of the proposed method has been investigated experimentally using seeded and naturally developed defects in gears and bearings. In addition, research into the optimal Wavelet Packet node that offers the best de-noising results has been performed showing that the 250-750 kHz band gives the best SNR results. The detection of shaft angular misalignment using Acoustic Emission has been investigated and compared with acceleration spectra. The results obtained show enhancements of AE in detection shaft angular misalignment over vibration analysis in SNR and stability with varying operational conditions.

A dissertation submitted to the Faculty of Engineering, University of the Witwatersrand, Johannesburg, in fulfillment of the requirements for the degree of Master of science in Engineering. Johannesburg, 1992. / This project involves the comparison of different failure criteria with experimental results for fibre composite materials, and investigates the usefulness of acoustic emission in composite testing. Three sets of specimens were tested to failure in tension. The specimens had various ply orientations and were tested using acoustic emission to determine ply failures. Carbon and glass fibre reinforced epoxy pre-impregnated specimens were used. The testing machine was an ESH testing machine, and a physical Acoustics corporation computer and data acquisition unit were used to record data from a piezo-electric sensor. Suitable failure criteria should be chosen on the basis of ply orientation and material type (eg fibre stiffness), a combination of criteria being used if necessary. Acoustic emission was successfully used to detect ply failure in multi-layered laminates. / AC2017

Historicamente, as atividades de manutenção têm sido caracterizadas como um problema dentro das organizações. Entretanto, nos últimos anos, esta atitude tem sido revista e tem levado a um reconhecimento da manutenção como uma função estratégica nas empresas. Esta mudança do papel da manutenção é fruto da globalização de mercados, que forçam as organizações a competir não somente em qualidade, diferenciação ou preço, mas também, em inovações tecnológicas, redução de tempo de atendimento e tecnologia de informação. A informação é um recurso essencial para direcionar e atingir os objetivos da gestão. No caso da manutenção, a coleta e análise de dados são recursos indispensáveis para o monitoramento e controle de suas atividades. O sistema proposto visa o atendimento dessas expectativas, através da aquisição de dados por sensores de emissão acústica em equipamentos rotativos. A pesquisa buscou a confirmação de que é possível a detecção de falhas em mancais de rolamentos, a partir do monitoramento dos níveis de emissão acústica, e assim conseguir uma forma pró-ativa de gerir a manutenção. A análise dos dados coletados fornece parâmetros para que se possam gerar informações que disparem ações, tanto do departamento de manutenção como dos demais setores envolvidos (direta ou indiretamente) com suas atividades, de maneira integrada. / Historically, the maintenance activities have been characterized as a problem for the organizations. However, in the last years, maintenance has been recognized as strategic for the enterprises. This change in the role played by maintenance is a result of the globalization of markets that force the organizations to compete not only in quality, prices, but also in technology innovation, time to market and information technology. Information is an essential resource for achieving the objectives of managing. Regarding to maintenance, the gathering and analysis of data are of fundamental importance for the monitoring and control of the related activities. The system proposed in this research has the objective of improving the managing of maintenance through the data acquisition of acoustic emission in rotary equipments. This research aims at the confirmation of the possibility of monitoring failure in ball bearings though the monitoring of acoustic emission and from this information to manage the maintenance processes. The analysis of the collected data offered parameter for the generation of a list of integrated actions for the maintenance department as well other involved sectors of the company.

O objetivo deste trabalho é o desenvolvimento de um sistema de monitoramento capaz de identificar em processo o mecanismo de desgaste ao qual o rebolo está sendo submetido durante a retificação. Assim, inicialmente foram pesquisados os meios físicos, os tipos de sensores e estratégias utilizadas nos sistemas de monitoramento, o estágio atual de desenvolvimento e suas aplicações. Para que este sistema seja confiável e eficiente foi necessário estudar detalhadamente a fenomenologia dos mecanismos de desgaste do rebolo. Este estudo permite definir parâmetros para identificação do tipo de desgaste que está ocorrendo, baseado em indicações fornecidas pelo monitoramento de variáveis cujo comportamento é conhecido, como potência consumida pelo motor do rebolo e vibração ou ainda por medições metrológicas. Dois sistemas ópticos de mapeamento da superfície do rebolo são apresentados e estes sistemas serviram como base para o desenvolvimento de um novo sistema de mapeamento da Distribuição da Energia Acústica de Retificação no rebolo, DEAR. Realizaram-se experimentos com o novo sistema, monitorando simultaneamente outros meios físicos. Procurou-se desta forma relacionar o padrão gráfico do mapa gerado pelo novo sistema com o tipo de desgaste que estava ocorrendo, baseado nas informações obtidas no estudo dos mecanismos de desgaste. A análise dos resultados mostraram que o mapa DEAR pode ser utilizado para identificar o tipo de mecanismo de desgaste predominante que está ocorrendo no rebolo, em processo. Esta informação é muito útil na escolha de ações corretivas para problemas da retificação. / The objective of this work is the development of a monitoring system able to identify in process the grinding wheel wear mechanism. Thus, initially the physical quantities, sensors types and monitoring systems strategies, developing status and their applications were researched. To get a reliable and efficient system was necessary a detailed study of the grinding wheel wear mechanism phenomenology. This study allows to define parameters in order to identify which type of wear is occurring, using indication obtained by the monitoring variables whose behavior is known, such as grinding power, vibration or metrological measurement. Two grinding wheel surface optical mapping systems are presented, those systems were utilized as base to developing a new mapping system of Grinding Acoustic Energy Distribution (DEAR). Experiments have been done with the new system, monitoring simultaneously other physical quantities, looking for a way to link the mapping graphic patterns generates by the new system with the wear type which was occurring, based on information obtained from the wear mechanism study. The results and analysis have shown that the DEAR map can be used to identify the predominant wear mechanism type which is occurring on a grinding wheel, in process. This information is very useful in the corrective actions when facing a grinding problem.