Potentials of in situ monitoring of aluminum alloy forging by acoustic emission

authored by: Bernd Arno Behrens, Anas Bouguecha, Christian Buse, Kai Wölki, Adrian Santangelo
Abstract: Deviations during forging processes lead to workpiece failure when the forming limits of the material are exceeded. In production processes an early detection of manufacturing faults is preferred. The acoustic emission (AE) technique is examined with respect to its ability to detect deviations in lubrication conditions and in the structural integrity of different aluminum part geometries and alloys during forming. In a first step, an upsetting of varying specimen shapes was performed in order to study correlations of occurring defects as well as changing friction conditions with acoustic emission response. Afterwards, a cross joint was forged and AE was analyzed. The results suggest that crack detection during forging is feasible but limited by material ductility. In addition, it is shown that the characteristics of the acoustic emission during forming strongly depend on the respective alloy. With respect to faultless warm forging it is found that different stages are reflected in the AE signal, facilitating the detection of process deviations.
Organisation(s): Institute of Metal Forming and Metal Forming Machines
Type: Article
Journal: Archives of Civil and Mechanical Engineering
Volume: 16
Pages: 724-733
No. of pages: 10
ISSN: 1644-9665
Publication date: 01.06.2016
Publication status: Published
Peer reviewed: Yes
ASJC Scopus subject areas: Civil and Structural Engineering, Mechanical Engineering
Electronic version(s): https://doi.org/10.1016/j.acme.2016.04.012 (Access: Closed)
: Details in the research portal "Research@Leibniz University"

BibTeX

@article{630017642dda439795e3f86c531bd623,
title = "Potentials of in situ monitoring of aluminum alloy forging by acoustic emission",
abstract = "Deviations during forging processes lead to workpiece failure when the forming limits of the material are exceeded. In production processes an early detection of manufacturing faults is preferred. The acoustic emission (AE) technique is examined with respect to its ability to detect deviations in lubrication conditions and in the structural integrity of different aluminum part geometries and alloys during forming. In a first step, an upsetting of varying specimen shapes was performed in order to study correlations of occurring defects as well as changing friction conditions with acoustic emission response. Afterwards, a cross joint was forged and AE was analyzed. The results suggest that crack detection during forging is feasible but limited by material ductility. In addition, it is shown that the characteristics of the acoustic emission during forming strongly depend on the respective alloy. With respect to faultless warm forging it is found that different stages are reflected in the AE signal, facilitating the detection of process deviations.",
keywords = "Acoustic emission testing, Aluminum alloy, Forging, Process monitoring",
author = "Behrens, {Bernd Arno} and Anas Bouguecha and Christian Buse and Kai W{\"o}lki and Adrian Santangelo",
note = "Funding information: The presented work is a result of the project “Online-{\"U}berwachung von Schmiedeprozessen mittels akustischer Emissionsanalyse”, project number BE1691/78-2, granted by the German Research Foundation (DFG) The authors are thankful for the financial support. Thanks to Institut f{\"u}r Werkstoffkunde (Materials Science), Leibniz Universit{\"a}t Hannover, for scanning electron microscope images.",
year = "2016",
month = jun,
day = "1",
doi = "10.1016/j.acme.2016.04.012",
language = "English",
volume = "16",
pages = "724--733",
journal = "Archives of Civil and Mechanical Engineering",
issn = "1644-9665",
publisher = "Elsevier BV",
number = "4",
}