A PANEUROPEAN PROJECTS FOR THE THERMAL TESTING OF THE MATERIALS

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1 A PANEUROPEAN PROJECTS FOR THE THERMAL TESTING OF THE MATERIALS Lenka KŇAZOVICKÁ a, b, Radek STRNAD a a Czech Metrology Institute, Okružní 31, Brno, Czech Republic, EU, lknazovicka@cmi.cz, rstrnad@cmi.cz b ICT in Prague, Prague, Czech Republic, EU Abstract This paper describes the projects started (and anticipated) in the European Metrology Research Programme (EMRP). Czech Metrology Institute (CMI) is an active EMRP partner in solving problems in various fields. Department of Thermal Properties, mostly focusing on the temperature measurements, is involved in 4 EMRP project, deals with construction materials. First one, already running, is a project focused on industry called HITEMS. One part of this project deals with the properties determination of the materials used in steel or glass industry. Another three projects are in preparation. One project will be focused on the non-destructive methods suitable for defect detection of fibre-reinforced plastic composites for primary load bearing and safety critical applications, such as commercial aircraft, bridges and off-shore platforms. For the defect detections will be used microwave, thermography, laser shearography and ultrasonics. Next project is focused on development of new materials with improved resistance to high temperature particulate erosion. This will be high valuable in the manufacture of power generating plant and aeroengines. The last project is focused on the thermophysical property data for thermal protection materials, such as advanced insulation and composites, which are essential for modelling the heat transfer in aerospace, structural fire safety and processing applications. Keywords: EMRP, Emissivity, Non-destructive detection methods, Erosion, Thermophysical properties 1. INTRODUCTION Knowledge of the exact temperature of the material is important, sudden change of the material temperature can indicate defect of the material or mistake in the industrial process. In many cases, measurement of the temperature in practice is big challenge, because of the non-ideal conditions high temperatures, dirty environment, poorly available spaces for direct measurements by contact thermometers, thermometers with low possibilities of the calibration. But it is in the interest of all, to solve these problems best as possible with minimal financial costs. European Metrology Research Programme provides great opportunity for new researches in a wide field of interests, and allows international cooperation between researches institutes. Industrial partners are also important for these projects, they provide valuable feedback to developed methods and solutions, and also can be actively involved in the projects. 2. HITEMS PROJECT Industrial project called High temperature metrology for industrial applications, is focusing on solving problems united with processes, where temperatures higher than 1000 C are necessary (e.g. glass, steel,

2 aerospace industry). Project started in September 2011, and several problems are solved in two main thermometry areas [1, 2]. Non-contact thermometry is mainly focused in: Emissivity and reflected radiation, with the target of achieving in-situ traceability Corrections for varying window/path transmission, to approximately 2500 ºC Real time traceable temperature measurement in laser materials processing Contact thermometry: Lifetime assessment of base metal and drift measurements of base and noble metal thermocouples Self-validation and demonstrated in-situ validation for temperature sensors to at least 2000 ºC Facility for determination of reliable reference functions for high temperature non-standard thermocouples (shown by determining a better reference function for the Ir-60%Rh/Ir thermocouple) In a lot of processes, knowledge of the right temperature is essential because it influences manufacturing process directly. CMI is involved in HITEMS project in emissivity measurements for different types of material. Knowledge of the material emissivity is very important; without this information is impossible correctly measure the temperature of the material surface. 3. NDECOMP PROJECT Project named Development of Novel Non-Destructive Evaluation Techniques and Procedures for Defect Detection in Composite Structures, is whole focused in non-destructive detection and characterisation of the fibre-reinforced plastic composites used for primary load bearing and safety critical applications, such as commercial aircraft, bridges and off-shore platforms. This project will develop and validate operational and calibration procedures for novel NDE (non-destructive evaluation) techniques to assess the detection, location and sizing of a range of defects in composite structures. These procedures would be expected to lead to improvements in safety, life expectancy, energy efficiency and sustainability, as well as reductions in maintenance costs This project will focus on traceable measurement and characterisation of novel NDE techniques, and procedures for defect detection, location and sizing, for composite structures. The specific objectives are: 1) To design and manufacture suitable reference defect artefacts (RDAs) that are representative of the materials and defects typically found in the aerospace, oil and gas, renewable energy, marine, transport and civil infrastructure sectors. 2) To develop operational procedures, drafted in the style of CEN and ISO standards, for microwave, active thermography, laser shearography, and phased array ultrasonic techniques. The metrology objectives are to: a. Comprehensively assess the probability of detection (POD) of each NDE technique for the different defect types found in various composite material systems and formats. b. Establish the limits of detection for each technique i.e. the minimum sizes of defects that can be detected. c. Develop techniques for accurately sizing defects for the NDE techniques. The NDE results will be compared with independent characterisation. 3) To evaluate the POD methodology based on modelling simulations with the aim of reducing the cost and time requirements of POD trials. 4) To validate and refine operational procedures via intercomparison exercises and field trials in collaboration with industry. RDAs will be inspected using both in-house inspection techniques and the newly developed operational procedures.

3 This project is now in preparation (like the two other projects described below) and if successful, the projects will run from CMI will participate in part dealing with active thermography and thermal characterisation of the samples. 4. METROLOGY TO ENABLE HIGHT TEMPERATURE EROSION TESTING PROJECT (METROSION) The project aims to develop significantly improved test protocols implementing state of the art in-situ metrology for the measurement of high temperature solid particle erosion, requiring traceable measurement of mass, volume, flow, velocity, temperature and shape. It significantly improves the measurements and control of high temperature solid particle erosion testing and will greatly enhance the modelling capability for erosion. This is illustrated in the following description of some of the key actions of proposed workpackages. Workpackage 1 will provide the necessary materials for the use within the project, consisting of coated and uncoated substrates. These will be metallographically characterised before use such that the subsequent erosion processes can be clearly identified. Workpackage 2 will focus on the development of a new test apparatus which can be used to perform the in-situ measurements incorporating the latest measurement technology. This workpackage will also characterise the effect of key experimental variables and conduct an interlaboratory exercise to determine the repeatability and reproducibility of erosion data between different establishments. Using the data from this rig, models of erosive wear will be developed making use of the improved test method and metrology. Workpackage 3 is a core metrology activity and is concerned with the development of improved measurements of wear volume and mass, and also to develop techniques to evaluate the size, size distribution and shape of erodent particles. Workpackage 4 will focus of the measurement of environmental parameters such as particle and gas velocity, temperature and flow. Workpackage 5 is designed to maximise the impact for the JRP through dissemination, knowledge transfer, training and creating links to industrial stakeholders. Uptake of the results of this project will enable manufacturing industry to develop new power generation plant and aero-engine propulsion units with improved energy efficiency and durability, thereby, improving the competitiveness of European industry, reducing impact on the environment and improving the quality of life for European citizens. 5. METROLOGY FOR THERMAL PROTECTION MATERIALS PROJECT Recent developments in polymer, aerogel and fibrous based composite systems used for thermal protection have the potential to provide thermal performance that is several-fold better than conventional insulation materials, but there is currently no reliable metrology framework with which to evaluate their performance, including validation of their use in safety critical engineering. Measurements using existing industrial techniques have shown significant level of scatter, sometimes over 100% for these new types of thermal protection. The lack of traceability in thermal performance metrology results in the advanced manufacturers not having the confidence to invest in these new materials and/or not being able to demonstrate their performance to engineering certification authorities. Traceable qualification of improvements in high-performance thermal protection systems will have significant and far reaching impact across most of Europe s Key Enabling Technologies and industries. Requirements

4 for validated and traceable measurements are especially critical in advanced manufacturing industries such as aerospace and in safety systems for industrial facilities and transportation, where a lack of reliable thermal property data leads to either extra cost from over engineering or a higher risk of industrial disasters. Despite European government having spent the last fifteen years putting into place new regulations (EU NO. 305/2011) and mandatory standards (including EN to EN 14309) with the aim of making accurate thermal performance data available to industrial users, the current level of agreement between reference laboratories is still three times worse than the maximum 5 % allowed in these regulations. Implementation of these regulations urgently requires the science underpinning thermal conductivity measurements to undergo a step-change improvement. The proposed project will establish a thermal conductivity measurement infrastructure that addresses the whole traceability chain. It will aim to achieve three times better agreement between reference laboratories and evaluate the viability of improving transient and other industrial measurement techniques up to 800 C: Work Package 1 will develop new techniques for the next generation of national standard instruments. Work Package 2 will identify, develop and quantify the first of their kind reference materials with a thermal conductivity in the range 0.02 W m -1 K -1 to 1 W m -1 K -1 and covering temperatures up to 800 C. Work Package 3 will systematically investigate the limitations of the transient and other industrial techniques. Work Package 4 will for the first time theoretically and numerically determine the effect of radiant heat transfer on thermal conductivity measurement of low density material. Work Package 5 will ensure that the knowledge generated within the project will be disseminated to other reference laboratories, industrial users, standards organisations and engineering designers. The outcomes of this project will immediately provide the metrology that is urgently needed to implement the new European regulations for insulation of industrial installations and enable European manufacturers to meet mandatory CE marking requirements. Further dissemination to the scientific and technological developments will be driven by the projects collaborators, which include several multinational aerospace companies; materials manufacturers and their European trade association; a regulatory scheme for European commercial laboratories; and a CEN standards committee. NIST have also identified improved measurement and traceability as a priority for these materials and so will also participate in the project. This JRP is directly aligned with the EMRP Outline 2008, as it proposes a European thermal conductivity metrology infrastructure and traceability that is crucial to ensure compliance with a single European market and to strengthen the competitive position of European enterprises in the global marketplace. It is also essential for enabling implementation of new European regulations and mandatory product standards. This metrological infrastructure can only be achieved by bringing together expertise from across national measurement institutes and is too widely applicable to be funded by a single industry. EMRP is currently the only appropriate funding mechanism with which to develop this essential European metrology. 6. CONCLUSION The paper presents Pan-European projects, which solves the challenges connected with thermal behavior of the different materials. Projects are partly funded by European Union through the European Metrology Research Programme (EMRP). One of the main reasons of existence of these projects is cooperation between National Metrology Institutes across whole Europe. These projects also provide valuable information from research universities and collaboration with industrial partners.

5 ACKNOWLEDGEMENT This work is part funded by the EMRP. The EMRP is jointly funded by the EMRP participating countries within EURAMET and the European Union. LITERATURE [1] MACHIN, G., ANHALT, K., EDLER, F, PEARCE, J., SADLI, M., STRNAD, R., VUELBAN, E., HiTeMS: A Project To Solve High Temperature Measurement Problems in Industry, 9 th International Temperature Symposium, , Anaheim, CA, USA [2] STRNAD, R. Projekt HiTeMS, Automa, 2011, číslo 11 s. 49