A.J. Huijer
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1
Society increasingly demands that ships become more sustainable and quieter, given their significant share of global fuel consumption and green-house gas emissions. Fiber-reinforced composite marine propellers can contribute meaningfully to these goals. As a promising alternative to the conventional rigid metallic propellers, flexible composite propellers can offer improved underwater radiated noise (URN) and propulsion efficiency. Furthermore, manufacturing propellers from fibre-reinforced composite materials makes them lighter and reduces their electromagnetic signature.
Despite the significant potential of composite propellers for marine propulsion systems, uncertainties in their fatigue behaviour have so far hindered their wide-spread adoption. These uncertainties can arise from imperfections during the manufacturing process, operational conditions different than the ones considered in the design, coating deterioration leading to water ingress, impact events, and more. Such factors can have significant impact on the lifetime of the propeller, which is typically expected to endure billions of cycles. Structural health monitoring (SHM) has the potential to mitigate this issue by real-time recording and assessing the structural response and integrity of the propeller. Such an SHM system should neither affect the propeller performance nor its load-bearing capacity. In addition to providing insights into the current structural integrity of the propeller, an SHM system may also enable enhanced estimation of the remaining lifetime, thereby minimizing the risk of unexpected failures and downtime.
This thesis investigates the feasibility of developing composite marine propellers with an embedded SHM system based on piezoelectric sensors. These sensors are capable of performing strain monitoring (with application in load/response estimation) and acoustic emission monitoring (with application in damage identification). Three main topics have been studied; (i) the feasibility of measuring dynamic strains in the propeller blade using the embedded sensors, (ii) the effect of embedding piezoelectric sensors on the structural integrity, and (iii) the feasibility of measuring and assessing damage-induced acoustic emissions using the embedded sensors. An analysis framework has been proposed for the identification, classification, and localisation of acoustic emissions in thick composite structures…
...
Despite the significant potential of composite propellers for marine propulsion systems, uncertainties in their fatigue behaviour have so far hindered their wide-spread adoption. These uncertainties can arise from imperfections during the manufacturing process, operational conditions different than the ones considered in the design, coating deterioration leading to water ingress, impact events, and more. Such factors can have significant impact on the lifetime of the propeller, which is typically expected to endure billions of cycles. Structural health monitoring (SHM) has the potential to mitigate this issue by real-time recording and assessing the structural response and integrity of the propeller. Such an SHM system should neither affect the propeller performance nor its load-bearing capacity. In addition to providing insights into the current structural integrity of the propeller, an SHM system may also enable enhanced estimation of the remaining lifetime, thereby minimizing the risk of unexpected failures and downtime.
This thesis investigates the feasibility of developing composite marine propellers with an embedded SHM system based on piezoelectric sensors. These sensors are capable of performing strain monitoring (with application in load/response estimation) and acoustic emission monitoring (with application in damage identification). Three main topics have been studied; (i) the feasibility of measuring dynamic strains in the propeller blade using the embedded sensors, (ii) the effect of embedding piezoelectric sensors on the structural integrity, and (iii) the feasibility of measuring and assessing damage-induced acoustic emissions using the embedded sensors. An analysis framework has been proposed for the identification, classification, and localisation of acoustic emissions in thick composite structures…
...
Society increasingly demands that ships become more sustainable and quieter, given their significant share of global fuel consumption and green-house gas emissions. Fiber-reinforced composite marine propellers can contribute meaningfully to these goals. As a promising alternative to the conventional rigid metallic propellers, flexible composite propellers can offer improved underwater radiated noise (URN) and propulsion efficiency. Furthermore, manufacturing propellers from fibre-reinforced composite materials makes them lighter and reduces their electromagnetic signature.
Despite the significant potential of composite propellers for marine propulsion systems, uncertainties in their fatigue behaviour have so far hindered their wide-spread adoption. These uncertainties can arise from imperfections during the manufacturing process, operational conditions different than the ones considered in the design, coating deterioration leading to water ingress, impact events, and more. Such factors can have significant impact on the lifetime of the propeller, which is typically expected to endure billions of cycles. Structural health monitoring (SHM) has the potential to mitigate this issue by real-time recording and assessing the structural response and integrity of the propeller. Such an SHM system should neither affect the propeller performance nor its load-bearing capacity. In addition to providing insights into the current structural integrity of the propeller, an SHM system may also enable enhanced estimation of the remaining lifetime, thereby minimizing the risk of unexpected failures and downtime.
This thesis investigates the feasibility of developing composite marine propellers with an embedded SHM system based on piezoelectric sensors. These sensors are capable of performing strain monitoring (with application in load/response estimation) and acoustic emission monitoring (with application in damage identification). Three main topics have been studied; (i) the feasibility of measuring dynamic strains in the propeller blade using the embedded sensors, (ii) the effect of embedding piezoelectric sensors on the structural integrity, and (iii) the feasibility of measuring and assessing damage-induced acoustic emissions using the embedded sensors. An analysis framework has been proposed for the identification, classification, and localisation of acoustic emissions in thick composite structures…
Despite the significant potential of composite propellers for marine propulsion systems, uncertainties in their fatigue behaviour have so far hindered their wide-spread adoption. These uncertainties can arise from imperfections during the manufacturing process, operational conditions different than the ones considered in the design, coating deterioration leading to water ingress, impact events, and more. Such factors can have significant impact on the lifetime of the propeller, which is typically expected to endure billions of cycles. Structural health monitoring (SHM) has the potential to mitigate this issue by real-time recording and assessing the structural response and integrity of the propeller. Such an SHM system should neither affect the propeller performance nor its load-bearing capacity. In addition to providing insights into the current structural integrity of the propeller, an SHM system may also enable enhanced estimation of the remaining lifetime, thereby minimizing the risk of unexpected failures and downtime.
This thesis investigates the feasibility of developing composite marine propellers with an embedded SHM system based on piezoelectric sensors. These sensors are capable of performing strain monitoring (with application in load/response estimation) and acoustic emission monitoring (with application in damage identification). Three main topics have been studied; (i) the feasibility of measuring dynamic strains in the propeller blade using the embedded sensors, (ii) the effect of embedding piezoelectric sensors on the structural integrity, and (iii) the feasibility of measuring and assessing damage-induced acoustic emissions using the embedded sensors. An analysis framework has been proposed for the identification, classification, and localisation of acoustic emissions in thick composite structures…
Journal article
(2024)
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M.G.A. Adams, A.J. Huijer, C. Kassapoglou, Johannes A.A. Vaders, Lotfollah Pahlavan
The multimodal and dispersive character of ultrasonic guided waves (UGW) offers the potential for non-destructive evaluation of fiber-reinforced composite (FRC) materials. In this study, a methodology for in situ stiffness assessment of FRCs using UGWs is introduced. The proposed methodology involves a comparison between measured wave speeds of the fundamental symmetric and antisymmetric guided wave modes with a pre-established dataset of UGW speeds and translation of them to corresponding stiffness properties, i.e., 𝐴𝐵𝐷-components, in an inverse manner. The dispersion relations of guided waves have been calculated using the semi-analytical finite element method. First, the performance of the proposed methodology has been assessed numerically. It has been demonstrated that each of the independent 𝐴𝐵𝐷-components of the considered laminate can be approximated with an error lower than 10.4% compared to its actual value. The extensional and bending stiffness properties can be approximated within an average error of 3.6% and 9.0%, respectively. Secondly, the performance of the proposed methodology has been assessed experimentally. This experimental assessment has been performed on a glass fiber-reinforced composite plate and the results were compared to mechanical tensile and four-point bending tests on coupons cut from the plate. Larger differences between the estimated 𝐴𝐵𝐷-components according to UGW and mechanical testing were observed. These differences were partly attributed to the variation in material properties across the test plate and the averaging of properties over the measurement area.
...
The multimodal and dispersive character of ultrasonic guided waves (UGW) offers the potential for non-destructive evaluation of fiber-reinforced composite (FRC) materials. In this study, a methodology for in situ stiffness assessment of FRCs using UGWs is introduced. The proposed methodology involves a comparison between measured wave speeds of the fundamental symmetric and antisymmetric guided wave modes with a pre-established dataset of UGW speeds and translation of them to corresponding stiffness properties, i.e., 𝐴𝐵𝐷-components, in an inverse manner. The dispersion relations of guided waves have been calculated using the semi-analytical finite element method. First, the performance of the proposed methodology has been assessed numerically. It has been demonstrated that each of the independent 𝐴𝐵𝐷-components of the considered laminate can be approximated with an error lower than 10.4% compared to its actual value. The extensional and bending stiffness properties can be approximated within an average error of 3.6% and 9.0%, respectively. Secondly, the performance of the proposed methodology has been assessed experimentally. This experimental assessment has been performed on a glass fiber-reinforced composite plate and the results were compared to mechanical tensile and four-point bending tests on coupons cut from the plate. Larger differences between the estimated 𝐴𝐵𝐷-components according to UGW and mechanical testing were observed. These differences were partly attributed to the variation in material properties across the test plate and the averaging of properties over the measurement area.
The marine industry is increasingly considering the use of flexible composite marine propellers for their potential to reduce carbon emissions and underwater radiated noise. Given the early stage of development of flexible composite propellers, there are unknowns on their structural degradation. Structural health monitoring (SHM) can provide additional insight into the occurrence and propagation of degradation in these structures. A passive and lightweight method of SHM is the measurement and processing of acoustic emissions (AE) that are induced by different degradation mechanisms. The current research investigates the measurement of AE signals in composite marine propeller blades using embedded piezoelectric sensors. A full-scale glass-fibre polymer composite propeller blade is suspended in a tank filled with artificial seawater. The propeller blade contains 24 embedded piezoelectric sensors that were installed between laminas during manufacturing. Additionally, the tank includes an array of hydrophones for validation of the results. AE signals are simulated on the blade using underwater pencil lead breaks. The measured AE signals are assessed for their amplitude and frequency content. The results demonstrate the feasibility of measuring AE signals in composite marine propeller blades using embedded piezoelectric sensors and hydrophones.
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The marine industry is increasingly considering the use of flexible composite marine propellers for their potential to reduce carbon emissions and underwater radiated noise. Given the early stage of development of flexible composite propellers, there are unknowns on their structural degradation. Structural health monitoring (SHM) can provide additional insight into the occurrence and propagation of degradation in these structures. A passive and lightweight method of SHM is the measurement and processing of acoustic emissions (AE) that are induced by different degradation mechanisms. The current research investigates the measurement of AE signals in composite marine propeller blades using embedded piezoelectric sensors. A full-scale glass-fibre polymer composite propeller blade is suspended in a tank filled with artificial seawater. The propeller blade contains 24 embedded piezoelectric sensors that were installed between laminas during manufacturing. Additionally, the tank includes an array of hydrophones for validation of the results. AE signals are simulated on the blade using underwater pencil lead breaks. The measured AE signals are assessed for their amplitude and frequency content. The results demonstrate the feasibility of measuring AE signals in composite marine propeller blades using embedded piezoelectric sensors and hydrophones.
Flexible composite marine propellers can aid the marine industry in reducing carbon emissions and underwater radiated noise pollution. The structural integrity of the blades can be assessed using structural health monitoring. One of these methods is the measurement and analysis of damage-induced acoustic emission signals. This paper experimentally investigates the feasibility of using embedded piezoelectric sensors for the measurement of acoustic emissions throughout a submerged flexible composite marine propeller blade. A full-scale glass-fibre reinforced polymer blade has been manufactured with 24 embedded sensors. While suspended in artificial seawater, acoustic emissions were simulated on the blade. The measurements show that the embedded piezoelectric sensors can measure acoustic emissions while the blade is submerged. Further, the distance from source to sensor over which the acoustic emission is measurable was investigated. For a noise level of 40 dB and a source amplitude of 70 dB between 100 and 250 kHz, an average maximum measurable distance of 124 mm was obtained. For higher frequencies, the distance drops and for lower noise levels the distance increases.
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Flexible composite marine propellers can aid the marine industry in reducing carbon emissions and underwater radiated noise pollution. The structural integrity of the blades can be assessed using structural health monitoring. One of these methods is the measurement and analysis of damage-induced acoustic emission signals. This paper experimentally investigates the feasibility of using embedded piezoelectric sensors for the measurement of acoustic emissions throughout a submerged flexible composite marine propeller blade. A full-scale glass-fibre reinforced polymer blade has been manufactured with 24 embedded sensors. While suspended in artificial seawater, acoustic emissions were simulated on the blade. The measurements show that the embedded piezoelectric sensors can measure acoustic emissions while the blade is submerged. Further, the distance from source to sensor over which the acoustic emission is measurable was investigated. For a noise level of 40 dB and a source amplitude of 70 dB between 100 and 250 kHz, an average maximum measurable distance of 124 mm was obtained. For higher frequencies, the distance drops and for lower noise levels the distance increases.
Journal article
(2023)
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Filippo Riccioli, A.J. Huijer, Nicola Grasso, Cesare M. Rizzo, Lotfollah Pahlavan
Measurement of transient pressure distribution on maritime structures is important for the assessment of the hydrodynamic loads applied. The commonly used pressure sensors are mostly bulky, need to be bolted to the structure, and/or only provide point-wise measurements. In this paper, an elastic matrix layer with a network of embedded piezoelectric sensors is proposed to address these issues. For experimental validation, a 400 × 400 × 5 mm epoxy layer is fabricated embedding 25 piezoelectric sensors on a square grid in accordance with Gauss-Lobatto-Legendre points. A finite element based inverse procedure is developed to reconstruct the pressure field from the electric potentials measured by the piezoelectric transducers. Feasibility of the concept is evaluated by measuring and reconstructing the pressure field generated by a travelling wave in a water tank. Sensitivity of the layer is also investigated through the experiments. The results indicate that the retrofit layer is capable of pressure field reconstruction, and that the presence of disturbances on the sensing surface does not affect the measurements in a notable way, while non-ideal conditions of the mounting can have a significant impact on the accuracy of the measurements. The results highlight the potential of the concept in pressure distribution measurements.
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Measurement of transient pressure distribution on maritime structures is important for the assessment of the hydrodynamic loads applied. The commonly used pressure sensors are mostly bulky, need to be bolted to the structure, and/or only provide point-wise measurements. In this paper, an elastic matrix layer with a network of embedded piezoelectric sensors is proposed to address these issues. For experimental validation, a 400 × 400 × 5 mm epoxy layer is fabricated embedding 25 piezoelectric sensors on a square grid in accordance with Gauss-Lobatto-Legendre points. A finite element based inverse procedure is developed to reconstruct the pressure field from the electric potentials measured by the piezoelectric transducers. Feasibility of the concept is evaluated by measuring and reconstructing the pressure field generated by a travelling wave in a water tank. Sensitivity of the layer is also investigated through the experiments. The results indicate that the retrofit layer is capable of pressure field reconstruction, and that the presence of disturbances on the sensing surface does not affect the measurements in a notable way, while non-ideal conditions of the mounting can have a significant impact on the accuracy of the measurements. The results highlight the potential of the concept in pressure distribution measurements.
Marine propellers made of fibre-reinforced composites have demonstrated the potential to outperform metallic propellers in terms of efficiency and under-water noise radiation. For full realisation of this potential in a tailored design process with realistic constraints, accurate information on the hydrodynamic loads acting on composite marine propellers and the structural integrity is of key importance. It is conceptualised that this information can be acquired without disturbing propeller hydrodynamics using a network of piezoelectric sensors embedded inside the blade. In this paper, feasibility of this concept has been investigated numerically and experimentally. Hydrodynamic loads on a composite propeller obtained from numerical simulations were used to assess the sensitivity of piezoelectric sensors in measuring the dynamic strain field due to the blade deformation. Subsequently, 25 small-scale carbon-epoxy composite samples were manufactured with embedded piezoelectric wafer sensors of different sizes, and subjected to non-destructive and destructive loading scenarios. Feasibility of measuring strains at different frequency ranges and damage-induced acoustic emissions was quantitatively assessed from these experiments. Furthermore, the influence of the embedded sensors on the ultimate strength and toughness of the specimens was investigated. It was found that at least 92% of the studied propeller blade would have dynamic strains measurable up to the first four harmonics by the considered piezoelectric sensors. In a four-point bending setup, it was additionally demonstrated that the embedded piezoelectric sensor captured damage-induced acoustic emissions up to specimen failure with an average signal to noise ratio of 17 dB. The results indicate that embedded piezoelectric sensor networks can have the capability to measure both low-frequency dynamic strains in composite marine propeller blades and damage-related acoustic emissions.
...
Marine propellers made of fibre-reinforced composites have demonstrated the potential to outperform metallic propellers in terms of efficiency and under-water noise radiation. For full realisation of this potential in a tailored design process with realistic constraints, accurate information on the hydrodynamic loads acting on composite marine propellers and the structural integrity is of key importance. It is conceptualised that this information can be acquired without disturbing propeller hydrodynamics using a network of piezoelectric sensors embedded inside the blade. In this paper, feasibility of this concept has been investigated numerically and experimentally. Hydrodynamic loads on a composite propeller obtained from numerical simulations were used to assess the sensitivity of piezoelectric sensors in measuring the dynamic strain field due to the blade deformation. Subsequently, 25 small-scale carbon-epoxy composite samples were manufactured with embedded piezoelectric wafer sensors of different sizes, and subjected to non-destructive and destructive loading scenarios. Feasibility of measuring strains at different frequency ranges and damage-induced acoustic emissions was quantitatively assessed from these experiments. Furthermore, the influence of the embedded sensors on the ultimate strength and toughness of the specimens was investigated. It was found that at least 92% of the studied propeller blade would have dynamic strains measurable up to the first four harmonics by the considered piezoelectric sensors. In a four-point bending setup, it was additionally demonstrated that the embedded piezoelectric sensor captured damage-induced acoustic emissions up to specimen failure with an average signal to noise ratio of 17 dB. The results indicate that embedded piezoelectric sensor networks can have the capability to measure both low-frequency dynamic strains in composite marine propeller blades and damage-related acoustic emissions.
The recording and processing of acoustic emissions can be used to identify and localise damage mechanisms occurring in engineering structures. In plate-like structures, acoustic emissions propagate through the structure as guided waves. With a measurement location away from the source location, dispersion effects in the guided wave distort the acoustic emission signal. The distortion of the original signal hampers identification of damage mechanisms. This research describes and assesses a method to reconstruct the original acoustic emission signal using dispersion compensation. Simulations and experiments are performed involving thick glass-fibre reinforced plastic laminates. The signal reconstruction on the simulated data gives a reasonable representation of the simulated signal at the location of interest. In the experimental case, similarity slightly degrades. Deviation in arrival time between original measurement and reconstruction is attributed to a possible discrepancy in material properties in reality versus the properties used in the reconstruction.
...
The recording and processing of acoustic emissions can be used to identify and localise damage mechanisms occurring in engineering structures. In plate-like structures, acoustic emissions propagate through the structure as guided waves. With a measurement location away from the source location, dispersion effects in the guided wave distort the acoustic emission signal. The distortion of the original signal hampers identification of damage mechanisms. This research describes and assesses a method to reconstruct the original acoustic emission signal using dispersion compensation. Simulations and experiments are performed involving thick glass-fibre reinforced plastic laminates. The signal reconstruction on the simulated data gives a reasonable representation of the simulated signal at the location of interest. In the experimental case, similarity slightly degrades. Deviation in arrival time between original measurement and reconstruction is attributed to a possible discrepancy in material properties in reality versus the properties used in the reconstruction.
Piezoelectric sensors can be embedded in carbon fibre-reinforced plastics (CFRP) for continuous measurement of acoustic emissions (AE) without the sensor being exposed or disrupting hydro- or aerodynamics. Insights into the sensitivity of the embedded sensor are essential for accurate identification of AE sources. Embedded sensors are considered to evoke additional modes of degradation into the composite laminate, accompanied by additional AE. Hence, to monitor CFRPs with embedded sensors, identification of this type of AE is of interest. This study (i) assesses experimentally the performance of embedded sensors for AE measurements, and (ii) investigates AE that emanates from embedded sensor-related degradation. CFRP specimens have been manufactured with and without embedded sensors and tested under four-point bending. AE signals have been recorded by the embedded sensor and two reference surface-bonded sensors. Sensitivity of the embedded sensor has been assessed by comparing centroid frequencies of AE measured using two sizes of embedded sensors. For identification of embedded sensor-induced AE, a hierarchical clustering approach has been implemented based on waveform similarity. It has been confirmed that both types of embedded sensors (7 mm and 20 mm diameter) can measure AE during specimen degradation and final failure. The 7 mm sensor showed higher sensitivity in the 350–450 kHz frequency range. The 20 mm sensor and the reference surface-bounded sensors predominately featured high sensitivity in ranges of 200–300 kHz and 150–350 kHz, respectively. The clustering procedure revealed a type of AE that seems unique to the region of the embedded sensor when under combined in-plane tension and out-of-plane shear stress.
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Piezoelectric sensors can be embedded in carbon fibre-reinforced plastics (CFRP) for continuous measurement of acoustic emissions (AE) without the sensor being exposed or disrupting hydro- or aerodynamics. Insights into the sensitivity of the embedded sensor are essential for accurate identification of AE sources. Embedded sensors are considered to evoke additional modes of degradation into the composite laminate, accompanied by additional AE. Hence, to monitor CFRPs with embedded sensors, identification of this type of AE is of interest. This study (i) assesses experimentally the performance of embedded sensors for AE measurements, and (ii) investigates AE that emanates from embedded sensor-related degradation. CFRP specimens have been manufactured with and without embedded sensors and tested under four-point bending. AE signals have been recorded by the embedded sensor and two reference surface-bonded sensors. Sensitivity of the embedded sensor has been assessed by comparing centroid frequencies of AE measured using two sizes of embedded sensors. For identification of embedded sensor-induced AE, a hierarchical clustering approach has been implemented based on waveform similarity. It has been confirmed that both types of embedded sensors (7 mm and 20 mm diameter) can measure AE during specimen degradation and final failure. The 7 mm sensor showed higher sensitivity in the 350–450 kHz frequency range. The 20 mm sensor and the reference surface-bounded sensors predominately featured high sensitivity in ranges of 200–300 kHz and 150–350 kHz, respectively. The clustering procedure revealed a type of AE that seems unique to the region of the embedded sensor when under combined in-plane tension and out-of-plane shear stress.