G.

Jothinathan
Project Consultant
CNDE_MDS
Mech.Engg.Dept.
IITM_Chennai 600 036
Guest Faculty
Dept. of Metallurgical and Materials Engineering
Indian Institute of Technology, Madras, Chennai 600 036

Email gj@iitm.ac.in
Ph. 98411 07465 GJ, IITM, Cheenai
Acoustic Emission Testing (AET)
1.0 Fundamentals
1.1.1 Principles / theory of acoustic emission testing
1.1.2 Sources of acoustic emissions
1.1.3 Equipment and material
1.2 Proper selection of acoustic emission technique
1.2.1 Instrumentation and signal processing
1.2.1.1Cables (types)
1.2.1.2 Signal conditioning
1.2.1.3 Signal detection
1.2.1.4 Noise discrimination( filtering hard & software)
1.2.1.5 Electronic technique
1.2.1.6 Attenuation materials
1.2.1.7 Data filtering techniques
1.3 Interpretation and evaluation of test results

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Threshold setting
Acoustic Emission Testing- Introduction & Applications

1.Introduction Definition
Basic Features of AET
2. Types of AE and AE Parameters
3. Kaiser and Felicity Effect
4.Advantages and limitations of AET
4. Illustration of application with eg of Fatigue Damage
5. Industrial Applications of AET
6. Source Location
7. AET is NDT method
8. Future of AET
9. Summary and Conclusion
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 Acoustic Emission Testing
Features of AET
1. Dynamic method of testing Capable of
detecting only active flaws
stable or dormant flaws however large it may
not be detected ( )

AE Probe

Activity because of impetus

tensile load- AET can detectStable and dormant flaw-
no activity and no AET
Unlike other methods, no signal is sent and
signal originates from the active regions- this
signal is indicative of dynamic condition
(Magnetic lines of force, ultrasonic waves,X-
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rays and gamma rays)
II.What is AE: Generation of elastic waves
from localised sources due to release of energy
The sources could be
1.Plastic deformation
2. Crack initiation and growth
3. Some metallurgical changes etc
Any rearrangement of atoms & displacement as
low as 10-12 m can bring about AE
Examples of AE ( in the audible range)
1. Tin cry when deformed gives audible sound
2. Al-cu-Mg alloys-Luders Band- audible sound at meters
3. Martensite transformation audible sound used to
follow martensite transformation
Actual acoustic emission testing Ultrasonic frequency of
of 100 KHz to 40 MHz .
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III. What is AE Testing
Detection of elastic waves in the frequency range of
175 KHz to 30 MHz.- that is detection US waves
emitted from an active source or dynamic condition
Same Piezoelectric materials can be used as in the
case of UT .
Then what is the difference
Unlike UT, no signal is sent and only released US
waves are detected

Conventional AET system consists of a

piezoelectric transducer, preamplifiers, signal
conditioners,Analog to Digital Converters (ADC), a
computer and display unit as shown in Fig.1.
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Special features of AET
1. Capability to monitor active condition or
monitoring dynamic events

Any changes can be detected

2. Integrality of the technique Unlike other

methods, the detection is not confined to
probe dimensions(illustrate)

300 mts

Signal can be detected

Testing Limited probe even when the sensor is
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placement away from the source
 With the above two features, what could be
the potential applications of AET
1.On line monitoring or Continuous surveillance
etc
Nuclear power plants, Off-shore structures,
process industries need be monitored
continuously for integrity
Why important-forewarned to take remedial
measures

Set of probes placed suitably can indicate any changes taking

place in the structure and can remotely be monitored-
False alarm is not ruled out!!GJ, IITM, Cheenai
V. Why this promising method not that widely
used
External noises interfere.
VI. For successful applications, signal discrimination
and noise reduction are crucial
VII.Discrimination techniques pattern recognition
VI. An stimulus is necessary for the release of energy
and generation of acoustic emission
There are changes taking place in the
component during Acoustic emission
How this method is justified as a NDT method
AET is usually applied during loading or under service
condition and , AET detects the elastic waves radiated by a
growing fracture under the service conditions. Therefore, the
acoustic emission (AE) method should be considered to be a
"passive" non-destructive technique, because it is only able to
identify defects developing during the actual service and no
impetus is given for the testing
Location of the source
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Acoustic Emission Advantages
Entire structure can be monitored from a
few locations.
Structure can be tested in use.
Continuous monitoring with alarms is
possible.
Microscopic changes can be detected if
sufficient energy is released.
Source location is also possible using
multiple sensors.

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Acoustic Emission Applications
pipelines
storage tanks (above and below the ground)
fiberglass structures
rotating machinery
weld monitoring
Leak testing
biological and chemical changes

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 Types of AE and AE Parameters
Two types of AE signals- Continuous and burst type.
Burst signals, start and end points deviate clearly from
background With continuous AE signals, we can see
amplitude and frequency variations but the signal never
ends.

Burst emission Continuous emission

Continuous emission is measured as RMS voltage and normally
plastic deformation gives outGJ,continuous
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emission
AE parameters are useful in characterising the AE
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source. Low amplitude and high amplitude events
 Kaiser and Felicity effect
Plastic deformation is the primary source of AE in loaded
metallic structures.
Kaiser Effect,
AE occurs only when the stress level exceeds previous
stress level.
An effect in the case of composites is termed as 'Felicity effect'.
Felicity effect: Appearance of significant acoustic
emission at a load level below the previous maximum
applied level, e.g. as observed in composite materials.
~ ratio: Ratio between the applied load at which the
acoustic emission reappears during the next application
of loading and the previous maximum applied load

This ratio can be taken as good indicator of the

extent of damage GJ, IITM, Cheenai
 Illustration of application with example of Fatigue Damage

Three stages of fatigue

I Stage slip band formation and persistent slip bands
II Persistent slip bands lead to microcrack formation
III Microcracks coalece and leads to macrocrack - failure

The above processes are potential sources of AE

By monitoring AE signature, one can identify the
stage of fatifue life of the component

In other words, the components elapsed life can be

assessed by following the acoustic emission events at
any point of time
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 Industrial applications of AET

Acoustic emission is a very versatile, non-invasive way to

gather information about a material or structure.
Acoustic Emission testing (AET) is applied to inspect and
monitor pipelines, pressure vessels, storage tanks, bridges,
aircraft, and bucket trucks
A variety of composite and ceramic components can be
monitored.

It is also used in process control applications such as

monitoring welding processes. A few examples of
AET applications follow

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 On line monitoring of weld
The monitoring of welding during welding can lead to
considerable cost saving
In the case of resistance spot welding, AE can be used
for showing good and bad welds. weld quality
parameters such as strength and size of the nugget, the
amount of expulsion and the amount of cracking can
also be monitored
AE monitoring during welding
can detect : (1) Weld
cracking associated with
phase transformation, (2)
Nucleation and growth of
cracks during welding and
subsequent cooling e.g.,
delayed cracking, (3) Porosity
&inclusions, (4) Microfissuring,
(5)Cheenai
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and (6) Reheat cracks.
Corrosion monitoring by Acoustic emission

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 Pressure vessels for storage and transport of Hydrogen
Large area of commercial AE testing has been and still is tanks
and storage vessels, in particular pressure vessels. Pressure
vessels for storage or transport of hydrogen at high pressures
(> 700 bar) constitute another application both for proof-
testing (quality assurance) and periodic inspection after
defined service intervals.
AE monitoring of Bridges
Bridges contain many welds, joints and connections, and a
combination of load and environmental factors heavily
influence damage mechanisms such as fatigue cracking and
metal thinning due to corrosion. Acoustic Emission is
increasingly being used for bridge monitoring applications
because it can continuously gather data and detect changes
that may be due to damage without requiring lane closures or
bridge shutdown. In fact, traffic flow is commonly used to load
or stress the bridge for the AE testing

Bridges are fitted with

acoustic emission sensors
that listen for sounds of
cracks growing
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Aerospace Structures
Most aerospace structures consist of complex
assemblies of components that have been design to
carry significant loads while being as light as
possible. The detection of damage is extremely
important from safety point of view.
AET has found applications in monitoring the health of
aerospace structures because sensors can be attached in
easily accessed areas that are remotely located from
damage prone sites. (Inaccessible to traditional methods)

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Pattern recognition

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 Monitoring arrival time

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CODES AND STANDARDS IN AET
ASTM STANDARDS
E569 Acoustic Emission Monitoring of Structures
during Controlled Stimulation
E610 Definition of Terms Relating to Acoustic Emission
E650 Mounting Piezoelectric Acoustic Emission
Contact
Sensors
E749 Acoustic Emission Monitoring during Continuous
Welding
E750 Measuring the Operating Characteristics of
Acoustic
Emission Instrumentation
E751 Acoustic Emission Monitoring during Resistance
Spot Welding
E914 Test Method for Acoustic Emission for Insulated
Aerial Personnel Devices
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E976 Guide for Determining the Reproducibility of
Acoustic
Emission Sensor Response
E1067 Acoustic Emission Examination of Fiberglas
Reinforced
Plastic Resin (FRP) Tanks/Vessels
E1106 Primary Calibration of Acoustic Emission
Sensors
E1118 Acoustic Emission Examination of Reinforced
Thermosetting Resin Pipe (RTRP)
E1139 Practice for Continuous Monitoring of Acoustic
Emission from Metal Pressure Boundaries
E1211 Standard Practice for Leak Detection and
Location using Surface Mounted Acoustic Emission
Sensors
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 Couplant
Ensures good contact on microscopic level
between two surfaces transmission from the
surface to the sensor
High wettability
Corrosion resistance
Sufficient viscosity
Easy removal
Natural wax
Silicone grease
Epoxy resin
Propylene glycol
Waveguide
In some applications, it may not be possible to
place the sensor directly on the surface of the
component (e.g. in high temperature applications).
In such cases, a mechanical device called a
waveguide is used. This isolates the sensor from
the adverse environmental conditions while
maintaining acoustic communication from the
structure to the sensor. GJ, IITM, Cheenai
 CONCLUDING REMARKS
Acoustic Emission Technique
Structural Integrity
Pressure Testing storage tanks and vessels
Leakage
Crack Growth (Static and Fatigue)
Fabrication (Welding, Forming and Tool Wear)

Material Science Studies- Phase transformation

Strengthening mechanisms
Damage mechanisms
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Dr. Joseph Kaisers dissertation (about. 1950) at the Technical
University Munich was named: Examination about the
occurrence of sound at tensile tests. Due to his dissertation and
continuing research until his decease 1958, the Technical
University Munich is known as the origin of the AE-Technology.
There was very vigorous activity on AE Research and
application from 70 to 90. During this period the
usefulness of the method is exaggerated and this method
was considered panacea for all the problems connected
with monitoring integrity of the structures.
Then there was a period of near dull activity mainly
because of noise discrimination problem
Presently with high capability of computing and
advanced signal and image processing softwares,
process industries have started using this method
extensively Standards GJ,
- API
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Presently there is an increasing need for cost-effective
NDE techniques that can reduce the inspection and
maintenance costs in the refinery and petrochemical
industries.

AE techniques offer some potential advantages for

structural integrity assessments of industrial vessels.
Especially in the case of large-scaled vessels, where the
operating stresses have a tendency to activate defect
growth, the AE technique can effectively detect defect
activity and overstressed areas, in contrast to the static
conventional NDE techniques.

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Study Guide Qns
1. b. 100 300 KHz
2. d. all of the above
3. d attenuation
4. c AE only after the previous load is exceeded (normally in
metallic structures
5. a felicity ratio at variance with Kaiser effect ( FRP etc)

7. a Event & count

8. b
9. d
10. a

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