CHARACTERIZATION OF PLASTICALLY DEFORMED STEEL UTILIZING EMAT ULTRASONIC VELOCITY MEASUREMENTS P. D. Panetta1, B. Francini1, M. Morra1, G. A. Alers2, and K. Johnson1 Pacific Northwest National Laboratory, Richland, WA 99352 EMAT Consulting, San Luis Obispo, CA 93401 2 ABSTRACT. There is a desire to characterize plastically deformed regions in structures to monitor their integrity. Of particular importance is the accurate prediction of the lifetime of damaged pipelines due to outside force. In order to accurately predict the remaining life it is essential to accurately determine the degree stress and strain in the damaged region for input into fracture mechanics models. Currently, determination of the degree of stress and strain in damaged regions utilizing ultrasonic velocity measurements is complicated by the inherent texture in the materials and the difficulty in separating these effects from the stress and strain contributions. We will report ultrasonic velocity measurements on plastically deformed steel specimens to elucidate the state of damage. Specifically, we have found the shear wave birefringence and SH wave velocity are sensitive to the degree of plastic deformation. Ultrasonic results will be compared with finite element modeling calculation of the stress and strain distributions. INTRODUCTION Within the gas pipeline community, the characterization and detection of third party damage is of paramount importance. Several events occur when a pipe is mechanically damaged. Impacts from construction equipment cause dents and gouges to the pipe and the associated large plastic deformations and cold-working of the pipe surface. When the indenting force is removed, the dent can be partially rererounded by the internal pressure in the pipe. This partial removal of the dent is significant because it can place the coldworked surface in a high tensile stress state, which frequently cracks the surface. The presence of the gouge-in-dent dramatically increases the potential for crack initiation by (1) providing a geometric irregularity that concentrates the stresses, and (2) the cold-worked steel in the gouge now has a reduced ductility which can easily initiate cracks. Commonly used techniques for nondestructively determining the stress and strain in damaged materials typically rely on ultrasonic velocity measurements. Ultrasonic velocity is very sensitive to damage induced stress and strain and offers the potential for accurate quantitative determination of stress and strain as inputs into fracture mechanics models. This powerful combination offers a prognostic capability that is not currently available to pipeline inspection companies and utilities because of the lack of ability to accurately measure stress and strain. The main drawbacks include the fact that velocity is affected by competing sources of velocity shifts due to microstructural effects such as texture, CP657, Review of Quantitative Nondestructive Evaluation Vol. 22, ed. by D. O. Thompson and D. E. Chimenti © 2003 American Institute of Physics 0-7354-0117-9/03/S20.00 1516 temperature variations, the necessity for very precise time measurements, and low spatial resolution. Despite these drawbacks, ultrasonic measurements are valuable because they allow one to obtain information about the stress and strain in the interior of the materials as a function of depth. Typical ultrasonic measurement equipment is relatively inexpensive, portable, quick to set up, and the ultrasonic velocity data is rich with information. For these reasons the use of ultrasonic measurements to determine stress and strain has been an active area of research for many years. The ultrasonic velocities are related to the stress and texture by well-known equations. The relationship is governed by the acoustoelastic stress constants, three orientation distribution coefficients that describe the texture and the bulk and shear moduli. Algebraic equations with these seven unknowns can be compared with velocity measurements if enough measurements can be taken. For a longitudinal wave propagating in the thickness or the z-direction: pVp2z = B + ^ - oca +12.761W40o 3 (1) For a shear wave propagating in the z-direction and polarized in the axial direction: pVs2a = G - PC - [6.381W400 +10.089W420 ] (2) For a shear wave propagating along the z-direction and polarized in the circumferential or c direction: 2 (3) PVS C = G-jt7-[6.3810^ -10.089^420] In these equations, p is the density of the steel alloy, B and G are the bulk modulus and the shear modulus, respectively, of a hypothetical pipeline steel sample in which the grains are randomly oriented (the texture is zero), a, p, and y, are the acoustoelastic constants that are related to the Muraghan third-order elastic constants (TOEC) of the steel, and W4oo and W42o are the orientation distribution coefficients (ODCs) that describe the preferred orientation of the grains (the texture) in the particular section for the pipeline under study. Equations 1,2, and 3 represent three equations and five unknowns- B, G, o, W40o, and W42o- The three ultrasonic wave velocities are considered as known because they can be directly measured. The three acoustoelastic constants (a,|3, and y) could be measured in laboratory calibration experiments and the density p , can be taken from handbook values because it is a microstructure insensitive property of the steel involved. Clearly, more equations are needed to deduce the stress and texture contributions separately. When considering applications to characterizing dents and gouges in pipes it is important to realize that the stress and strain exhibit spatial variations and depth gradients. There are several different ultrasonic methods that are appropriate for this application, including through thickness measurements to characterize spatial gradients and waves with penetration depths that can be varied to characterize depth gradients. Thompson et al. [1] thoroughly reviewed the past several decades of research that utilized ultrasonic velocity measurements to characterize the stress and strain of materials. They reviewed the considerable progress in developing the scientific foundation underlying the techniques and highlighted specific results that have promise for various applications. One such result that is promising for characterizing inhomogeneous through-plate stress distributions is the work by King and Fortunko [2] based on the velocity measurements of horizontally polarized shear waves that were incident to the surface at shallow, grazing angles. The theoretical development exploits the relative insensitivity of the grazing shear wave propagation mode to texture and other microstructural anisotropies, compared to other wave propagation modes including bulk and Rayleigh modes. These 1517 results help to establish the fundamental scientific foundation and point to the need to improve spatial resolution for practical applications. Results by Thompson et al [3] applied many different types of waves generated by EMATs to accurately characterize the texture in aluminum and copper plates. Their experimental results agreed well with theoretical predictions for these plates under stress free conditions. In addition, the texture parameters obtained ultrasonically agreed well with x-ray determinations. Thompson et al. presented the theory and applications of the measurements of stress and texture in biaxially stressed specimens. [4]. Their measurements agreed well with theoretical predictions and form the scientific basis for characterizing biaxial stress states. Initial measurements performed by the authors have shown that through thickness measurements were strongly correlated with the strain in pipeline steels and experiments were performed which indicate that the stress and texture may have separable contributions to the velocity measurements. [5,6] Results were obtained while uniaxially loading a pipeline steel sample, which showed systematic changes in the shear wave birefringence during and after loading, which increased with increasing strain. Compression tests were also performed on the pipe and showed systematic differences in the birefringence between compression and tension that could easily be distinguished [6]. EXPERIMENTAL METHODS Velocity (Longitudinal, Ravleigh, Shear Horizontal) The longitudinal wave velocity was measured at the same locations as the shear wave birefringence. The velocity was determined from the time difference between successive echoes using the pulse echo overlap technique. For the Rayleigh wave velocity measurements, three electromagnetic acoustic transducers (EMATs) were used, one as a transmitter and two EMATs as receivers, see Figure 1. The SH-wave measurements were also performed in a pitch catch arrangement with one EMAT as the transmitter and one EMAT as the receiver, see Figure 1. The time of flight for the pitch catch measurements was also determined utilizing the pulse echo overlap method. Shear Wave Birefringence For practical detection and characterization of the plastically deformed regions in a structure such as a pipeline, the thickness cannot be assumed constant. Thus, it is desirable to use a measurement that is independent of the thickness. Therefore, the shear wave birefringence was measured, defined as the percent difference in time between the fast and slow mode for shear waves polarized along the principal axis of the material. The measurement was performed utilizing a rotating EMAT from Sonic Sensors, with the result being the time of flight between two echoes as a function of angle. Results are shown in Figure 2 for several levels of stress as will be described in the next section. R P — R SH Wave EMATs ~~~ R Rayleigh Wave EMATS FIGURE 1. A schematic of the SH and Rayleigh wave EMAT configurations. 1518 25.05 25.05 25.05 Max − Min Birefringe nce = - Max — Min Birefringence Average Max − Min Average Birefringence = Average 67 ksi 25.00 Arrival time (us) Arrival time (us) 25.00 25.00 4 24.95 24.95 67 ksi 24.95 24.90 24.90 0 ksi 24.90 47 ksi 33 ksi 47 ksi 27 ksi 33 ksi 13 ksi 27 ksi 13 ksi 0 ksi 24.85 24.85 0 24.85 90 90 180180 270270 Angle from axial direction Angle axial direction (degrees) 90 from 180 (degrees) 270 0 360360 360 Angle from axial direction (degrees) FIGURE 2. The timetime of flight as aasfunction of angle for for thethe pressurized pipe specimen. FIGURE 2. The of flight a function of angle pressurized pipe specimen. FIGURE 2. The time of flight as a function of angle for the pressurized pipe specimen. 1 1 0.8 0.6 0.4 0.2 0.8 0.8 15% 0.8 0.6 10% 5% Unloading 15% Unloading Plastic Plastic Strain Strain Effect Effect 0.6 0.6 10% 5% 0.4 0.4 0.4 Load Load Elastic Elastic Stress Stress Effect Effect 0.2 0.2 0.2 Loading Initial Initial Loading 0 0 0 0 20 2020 40 40 40 60 60 60 Tensile TensileStress Stress(ksi) (ksi) Tensile Stress (ksi) 80 80 0.0 Echo #4 Echo #4 0.0 0 5% Plastic Deformation 5%5% Plastic Deformation Plastic Deformation 10% Tensile Stress 10% Tensile Stress +Cσ Ca +DεDe B0B=B0 0=A=A+A+Cσ + +Dε Birefringence 1.2 Birefringence 1.2 Relative Birefringence Relative Birefringence RESULTS RESULTS RESULTS Measurements Measurementswere wereperformed performedononseveral severalspecimens, specimens, including including dogbones dogbones Measurements were performed on several specimens, including dogbones measuring 36 inches x 6 inches with a gage width of 4 inches, cut from steel measuring 36 inches x 6 inches with a gage width of 4 inches, cut froma a½”Vi"thick thick steel measuring 36 inches x 6 inches with a gage width of 4 inches, cut from a ½” thick steel plate. These dogbones were deformed in a tensile machine to 15% plastic deformation. plate. These dogbones were deformed in a tensile machine to 15% plastic deformation. plate. These dogbones were deformed in a deformation tensile machine toshown 15% deformation. Results of of the shear wave birefringence during areare ininFigure 3,3,where Results the shear wave birefringence during deformation shownplastic Figure where Results of the shear wave birefringence during deformation are shown in Figure 3, while where thethe shear wave birefringence as as a function stress shear wave birefringence a functionof of stressis isplotted plottedduring duringloading loadingand and while the shearAlso wave astheoretical atheoretical function predictions ofpredictions stress is for plotted during loading and while unloading. inbirefringence Figure 3 are plastic deformation the unloading. Also in Figure 3 are for5% 5% plastic deformation the unloading. Also in Figure 3asareantheoretical fordetermined 5% plastic from the constants in the equation, shown inset of of thepredictions graph constants in the equation, shown as an inset the graphwere were determineddeformation froma afitfittotothe the constants in the equation, shown as an inset of the graph were determined from a fit to the experimental data. While thethe fit fit is quite good, thethe terms A,A, CC and areare complex experimental data. While is quite good, terms andD D complexfunctions functions experimental data. While the fit is quite good, the terms A, C and D are complex functions of of materials parameters such as as elastic materials parameters such elasticmoduli, moduli,texture textureparameters, parameters,and andacoustoelastic acoustoelastic of materials parameters such as elastic moduli, texture parameters, and acoustoelastic constants. details calculation, publicationbybyThompson Thompsonetetal.al.[1]. [1].The The constants. ForFor details of of thethe calculation, seesee thethe publication constants. For details of the calculation, see the publication by Thompson et al. [1]. The birefringence first decreased as the load was applied, followed by and increase birefringence first decreased as the load was applied, followed by and increase birefringence first decreased as the load was applied, followed by and increase in inin birefringence at about 60 ksi after the materials began to plastically deform. The birefringence at about 60 ksi after the materials began to plastically deform. The birefringence at about 60 ksi after the materials began to plastically deform. The birefringence continued during unloading untilthethe theload loadwas wasremoved. removed. The The birefringence continued to to increase during unloading birefringence continued to increase increase during unloadinguntil until load was removed. The change ininthe as initial load was increased was due the acoustoelastic change in the birefringence as the initial load was increased was due tototo the acoustoelastic change thebirefringence birefringence as the the initial load was increased was due the acoustoelastic 0 10 10 20 20 20 30 40 30 40 5050 30 40 50 TensileStress Stress(ksi) (ksi) Tensile Tensile Stress (ksi) Echo #3 Echo #3 60 60 70 70 FIGURE3.3.The Theshear shearwave wavebirefringence birefringence as as aa function function of for the dogbones for various levels of FIGURE of stress stress dogbones various levels FIGURE 3. The shear wave birefringence as a function of stress for for thethe dogbones forfor various levels of of plasticstrain.. strain.. plastic plastic strain.. 1519 Change in Birefringence Change in Birefringence 0.7 0.7 0.6 0.6 Core 10 Core 10 PNNL Data PNNL Data 0.5 0.5 0.4 0.4 0.3 0.3 0.2 0.2 0.1 0.1 0 A36 Steel A36 Steel NIST Data NIST Data 0 0 00 0.05 0.1 0.15 0.2 0.05 0.1 0.15 0.2 0.2 0.05 0.1 0.15 Plastic strain (mm/mm) Plastic strain (mm/mm) Plastic strain (mm/mm) FIGURE 4. The change in the birefringence as a function of plastic strain for two different steel alloys. FIGURE 4. birefringence as aas function of plastic strain strain for twofor different steel alloys. FIGURE 4. The Thechange changeininthethe birefringence a function of plastic two different steel alloys. effect. Assuming that the specimen was stress free after unloading, the change in the birefringence before and the after unloading was due free to a after change in the texture accompanied effect. Assuming was stress unloading, the change in the in the effect. Assumingthat that thespecimen specimen was stress free after unloading, the change bybirefringence a residual strain. The change in the birefringence as a function of texture plastic accompanied strain for two before and after unloading was due to a change in the birefringence before shown and after unloading was due to a change in the texture accompanied different steel alloys in Figure The changeasina the birefringence the by a residual strain. isThe change in the 4. birefringence function of plasticincreased strain forastwo by a residual strain. The change in the birefringence as a function ofincreased plastic degree of plastic strainis increased indicating thatchange the birefringence is directly relatedstrain thefor two different steel alloys shown in Figure 4. The in the birefringence astothe different steel alloys is shown in Figure 4. The change in the birefringence increased degree in the specimens. the physics and related mathematical degreeofof plastic plastic strain strain increased indicating Understanding that the birefringence is directly to the as the degree of plastic strain increased indicating that the birefringence is directly related relationships of thisstrain correlation an importantUnderstanding goal of this work. degree of plastic in theisspecimens. the physics and mathematical to the degree of plastic strain in the specimens. Understanding themeasured physics as and mathematical relationships of this correlationwere is ancomplete, importantthe goalbirefringence of this work.was After the deformations at several relationships of this isthe anaxis important goal of this work. After the deformations were complete, was measured several5, locations separated by correlation 1 inch along of the birefringence dogbone. Results are shownasinatFigure locations separated by 1 inchtoalong the axis of the dogbone. Resultsshow are shown in Figure 5, several After thedeformed deformations were complete, theThe birefringence was as the at for the dogbones 5%, 10% and 15%. results anmeasured increase in for the dogbones deformed to 5%, 10% and 15%. The results show an increase in the birefringence in the gage wherethe theaxis mostofdeformation hasResults occurred, locations separated by 1region inch along the dogbone. arerelative showntointhe Figure 5, birefringence in the gage region the most deformation occurred, to thein in the grip regions. Also evident are small regions ofand residual asresults indicated byrelative aan decrease for the dogbones deformed to where 5%, 10% 15%.stress Thehas show increase gripbirefringence regions. Also evident regions of residual stress as indicated by a decrease in to the the Figure 5. small These results are in qualitative agreement with FEM birefringence in in the gage are region where the most deformation has occurred, relative the birefringence in Figure 5. These results are in qualitative agreement with FEM predictions, which also show small regions of residual stress at the locations where the grip regions. Also evident are small regions of residual stress as indicated by a decrease in predictions, which also show small regions of residual stress at the locations where the the birefringence in Figure 5. These results are in qualitative agreement with FEM predictions, which also show small regions of residual stress at the locations where the Before Unloading 1.0 Dogbone Relative Birefringence 0.8 1.0 After Unloading After Unloading After Unloading Before Unloading 15% 0.6 10% 0.4 0.8 Relative Birefringence Before Unloading Dogbone 5% 0.2 15% 0.6 0.0 0.40 5 15 10% 10 20 25 30 35 -0.2 Axial Stress Axial Stress Axial Stress Axial Stress Region with/ residual Regionstress with residual stress 5% Position 0.2 0.0 0 5 Regions with residual stress 10 15 20 25 30 Axial Strain Axial Strain 35 -0.2 Axial Stress Axial Stress Axial Strain FIGURE 5. The shear wavePosition birefringence (left) as a function of position and FEM Region(1” withseparation) residual FIGURE 5. The shear wavewith birefringence (left) as a function of position (1" separation) and FEM Regions stress predictions of the axial stress and strain. predictions of the axial stress and strain. residual stress FIGURE 5. The shear wave birefringence (left) as a function of position (1” separation) and FEM predictions of the axial stress and strain. 1520 Birefringence Birefringence 0.5 0.4 0.3 Variability with location (unloaded) 0.2 1.6 MHz 0.1 0.0 20 40 60 20 40Stress (ksi) 60 Circunferential Circunferential Stress (ksi) 0 Axial propagation !0.2995 0.2996 I0.2994 0.2995 - 1.88 MHz 1.88MHz I0.2993 0.2994 j,0.2992 0.2993 - Circumferential L-Wave Velocity (cm/us) Load 0.289 0.288 0.287 Unload 0.286 0.285 Cicumferential 0.284 0.283 10 20 30 40 50 60 0.29900- 10 10 SH-Wave Axial 0.290 "0.2990 0.2991 - 80 SH-Wave 0.291 SH-Wave Velocity (cm/us) 0.2997 0.2998 ,0.2996 0.2997 i j>0.2991 0.2992 - 0 0 Rayleigh Rayleigh 0.2998 Rayleigh Velocity (cm/us Birefringence 0.6 70 30 40 Stre ss (ksi) 30 40 20 50 60 70 50 L-Wave 0.5836 L-Wave 0.5832 5 MHz 0.5828 0.5824 0.5820 0.12% change 0.5816 0.5812 0 0 Stress (ksi) 20 20 20 40 40 Stress (ksi) 60 60 80 80 Stress (ksi) FIGURE 6. The velocity results while pressurizing the pipe with water in the elastic region to produce FIGURE 6. The velocity results while pressurizing the pipe with water in the elastic region to produce a biaxial stress state. a biaxial stress state. birefringence on birefringence decreased. decreased. These These results results are are also also inin agreement agreement with with measurement measurement on specimens performed by Panetta and Alers [6] specimens performed by Panetta and Alers [6] Measurements Measurementswere werealso alsoperformed performedon onportions portions of of natural natural gas gas pipelines, pipelines, provided provided bybyPacific Gas and Electric. These pipe specimens were approximately 6 Pacific Gas and Electric. These pipe specimens were approximately 6 feet feet in in length, length, 22 22 inches end and and inchesinindiameter, diameter,with witha awall wallthickness thicknessofof3/8 3/8inch. inch. The The pipe pipe was was capped capped on on each each end pressurized and pressurizedtotoininthe theelastic elasticregion regiontotoproduce produce aa biaxial biaxial stress stress state. state. Longitudinal Longitudinal and birefringence through birefringencemeasurements measurementswere wereperformed performed by bypropagating propagating the the ultrasonic ultrasonic waves waves through ehehthickness thicknessofofthe thepipe pipewall wallthickness, thickness,while while Rayleigh Rayleigh and and SH-waves SH-waves were were propagated propagated along alongthethepipe pipeaxis axisand andininthe thecircumferential circumferentialdirections. directions. Results Results as as aa function function of of stress stress are are shown in Figure 6 for the birefringence, Rayleigh wave, SH-wave, and longitudinal shown in Figure 6 for the birefringence, Rayleigh wave, SH-wave, and longitudinal waves. waves. Qualitatively, Qualitatively,the thechanges changesasasa afunction functionofofstress stressagree agreewith with published published results results [1] [1] with with the the SH-wave SH-wavepropagating propagatingininthe thecircumferential circumferentialdirection direction showing showing aa change change that that is is larger larger than than expected expecteddue duetotothe thelack lackofofadequate adequatemagnetization magnetization of of the the pipe pipe wall. wall Work Work is is currently currently underway underwaytotoovercome overcomethese thesemagnetization magnetization effects effects and and will will be be the the topic topic of of aa future future publication. publication. CONCLUSIONS CONCLUSIONS Theresults resultsshow showthat thatthe theultrasonic ultrasonicvelocity velocity isis sensitive sensitive to to small small changes in the The stressand andstrain strainofofalloys. alloys.The Thechange changeininthe thebirefringence birefringence before before and and after loading shows stress directcorrelation correlationwith withthe thedegree degreeofofplastic plastic strain strain inin the the materials. materials. The The ultrasonic ultrasonic a adirect velocitiesininpipe pipespecimens specimenswere weremeasured measuredwhile whilepressured pressuredtotoobtain obtain aa biaxial biaxial stress stress state. velocities The experimentalresults resultsare areininqualitative qualitativeagreement agreementwith withtheoretical theoreticalpredictions. predictions. The experimental 1521 ACKNOWLEDGMENTS The authors would like to thank Kayte Judd for performing key experimental measurements. The authors would also like to thank Dan Kerr from Pacific Gas and Electric for pipe specimens and access to their facilites. This work was supported by the Department of Energy's Natural Gas Infrastructure Reliability Program, operated by the National Energy Technology Laboratory. Pacific Northwest National Laboratory is operated for the U.S. Department of Energy by Battelle under Contract DE-AC0676RLO18310. REFERENCES 1. R.B. Thompson, W.-Y. Lu, and A.V. Clark, Jr. 1996. "Ultrasonic Methods." Chapter 7 in Handbook of Measurement of Residual Stresses. Eds. Dr. Jian Lu, pp. 149-178, The Fairmont Press, Inc., Lilburn, Georgia. 2. R.B. King, and C.M. Fortunko. 1984. Surface-residual-stress evaluation using horizontally polarized shear waves. J. Appl Phys. 55(11), p. 3978. 3. R.B. Thompson, J.F. Smith, S.S. Lee, and G.C. Johnson. 1989. "A comparison of ultrasonic and x-ray determinations of texture in thin Cu andAl plates" Metallurgical Transactions A, Volume 20A, pp. 2431 -2447. 4. R.B. Thompson, S.S. Lee, and J.F. Smith. 1986. "Angular dependence of ultrasonic wave propagation in a stressed, orthorhombic continuum: theory and application to the measurement of stress and texture." J. Acoust. Soc. Am. 80(3):921-931. 5. G.A. Alers and J.D. McColskey, "Measurement of residual stress in bent pipelines." in Review of Progress in Quantitative Nondestructive Evaluation, Vol. 21, eds .D.O. Thompson and D. I. Chimenti, American Institute of Physics, 2001, pp. 1681-1687. 6. P.D. Panetta and G.A. Alers, "Characterization of plastically deformed steel utilizing ultrasonic velocity and attenuation measurements", in Review of Progress in Quantitative Nondestructive Evaluation, Vol. 20, eds .D.O. Thompson and D. I. Chimenti, American Institute of Physics, 2000, pp. 1494-1500. PNNL-SA-33946, Pacific Northwest National Laboratory, Richland, WA. 1522
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