Measuring a load on a part and monitoring the integrity of the part

Abstract: A device for measuring the load on a part such as a bolt (2), and for monitoring the integrity of the part, comprises a socket (15) having walls defining an interior space (17) wherein the socket (15) engages the bolt (2) for transmitting a load to the bolt. An electromagnetic acoustic transducer (20) comprising a magnet (28) and a coil (26) is located in the interior space (17) of the socket (15) near the bolt (2). The coil (26) provides a current while the magnet (28) provides a magnetic field such that the magnet (28) and the coil (26) generate an ultrasonic signal within the bolt (2). A detector (25) is used to detect and measure a change in the ultrasonic signal at the bolt (2) for measuring the load on the bolt and for detecting any flaws in the bolt (2).

Description: The present invention relates to measurement of a load on a part and monitoring the integrity of the part, in particular using an electromagnetic acoustic transducer. A desired preload on a part such as a bolt is usually achieved during assembly of a structure by applying a specified torque to the bolt. It has been demonstrated that 90% of the torque applied to the bolt during assembly is used to overcome frictional forces. Small fluctuations in these frictional forces for a given fixed applied torque result in large fluctuations in the preload to the bolt. In a study of bolt preload versus applied torque for bolts used in the construction of the Space Shuttle Orbiter, a variation in bolt preload of more than a factor of two was reported for a given applied torque. Bolts having improper preloads can lead to catastrophic failure of critical components in a wide range of applications. Accordingly, ultrasonic methods using transducers have been developed in an effort to provide improved bolt load measurement. For example, when it was discovered that bolts used in reactor vessel internals in nuclear power plants were failing due to improper preload, an ultrasonic method was developed for setting the preload using standard ultrasonic transducers. This method was subsequently used in the replacement of these critical bolts in the nuclear power generation facilities. According to this previously-proposed method, the bolt preload is set by a precise measurement of the ultrasonic time of flight over the length of the bolt before and after tightening. While this method provides much improved bolt preload measurements compared to torque measurements, significant errors are introduced when removing and reapplying a transducer to the head of the bolt. Using standard ultrasonic transducers, sound waves are transmitted and received from the bolt via a coupling fluid. Because the velocity of sound in the couplant is many times slower than that of the steel, which is used in the bolt, small variations in the couplant path length can cause large variations in the transit time of the ultrasonic signal. The uncertainty introduced by the couplant path has limited most conventional ultrasonic bolt load measurements to measuring the time of arrival difference between successive echoes, which assumes that the couplant path transit time is identical for each echo. There would be several advantages in using only the first echo for ultrasonic bolt preload measurements. Primarily, the first echo is generally the largest, and less affected by lack of parallelism and flatness as compared to later echoes. For example, if the end of the bolt surface is at a small angle, , with respect to the head of the bolt surface, the first echo arrives at the head of the bolt at an angle of 2 while the second echo arrives at an angle of 6. The main drawback to these methods is that the all important application of couplant and transducer to the head of the bolt makes the automation of conventional ultrasonic bolt preload measurements a difficult task. The usefulness of conventional ultrasonic techniques for flaw detection and material property characterization is well established. Conventional piezoelectric ultrasonic methods have been employed for detection of cracks in bolts used in nuclear power plant reactor vessel internals and supporting structures. Generation of ultrasonic waves is achieved primarily by some form of electromechanical conversion, usually piezoelectricity. This method of generating ultrasound has a disadvantage in that it requires a fluid couplant to transfer sound mechanically into and out of the component being tested. The test object must be covered with a thin layer of fluid or immersed in the fluid, which complicates testing, often reduces the inspection rate, and can even introduce errors into the measurement. In some cases, the test may be impossible because of this requirement. Couplant clean up can be a significant problem in certain applications, and post-test corrosion of the component can be the cause of rejection in production. An ultrasonic technique that does not rely on a couplant has many advantages to offer. PCT-WO-95-22009 discloses a technique for measuring a load on a part, such as a bolt, utilising a socket for engaging and tightening the bolt. An electromagnetic acoustic transducer comprising a magnet and a coil is located in an interior space of the socket near the bolt-engaging area. A detector is used to detect and measure changes in the ultrasonic signal provided in the bolt by the magnet and the coil, so as to measure the tightening torque. US-A-4 295 377 discloses a threaded fastener incorporating a removable ultrasonic transducer for obtaining a preload measurement as well as other measurements for quality control or other monitoring purposes. The transducer is removable for repair or replacement. According to one aspect of the invention there is provided a device operable to verify material, alloy and heat treatment condition of a part immediately prior to loading and operable to measure a load on the part and continuously to monitor the integrity of the part before, during and after loading the part, the device comprising: means operable to engage the part, said engaging means having an interior space between the engaging means and the part; drive means operable to transmit a load to the part through said engaging means, said drive means being detachably engageable with said engaging means; a coil located in the interior space near the part and operable to introduce an eddy current in the part; means operable to provide current to said coil; a magnet engaging the coil in the interior space and being attached to.said drive means thereby to provide a magnetic field, the magnet and the coil generating a noncontact ultrasonic signal in the part; detection means operable to detect a change in the ultrasonic signal provided to the part; and display means responsive to the detection means to show any change in the ultrasonic signal indicative of a flaw in the part, wherein said display means in use is operable to compare the ultrasonic signal with a calibrated signal to verify material, alloy and heat condition treatment. According to another aspect of the invention there is provided a method of verifying material, alloy and heat treatment condition of a part immediately prior to loading and of measuring a load on the part and continuously monitoring the integrity of the part before, during and after loading the part, the method comprising the steps of: engaging the part with an engaging means such that an interior space is provided between the engaging means and the part; transmitting a load to the part with drive means through the engaging means, the drive means being detachably engageable with the engaging means; attaching a magnet with a coil to the drive means so that the magnet and coil are positioned in the interior space of the engaging means; generating a magnetic field in the interior space of the engaging means; providing a current in the interior space such that the current and the magnetic field produce a noncontact ultrasonic signal in the part; monitoring the ultrasonic signal in the part; detecting a change in the ultrasonic signal; displaying any detected change in the ultrasonic signal indicative of a flaw in the part; and comparing the ultrasonic signal with a calibrated signal for verifying material, alloy and heat treatment condition for the part. In a preferred embodiment of the invention, the device comprises a socket having walls defining an interior space, the socket engaging the bolt for transmitting a load to the bolt. An electromagnetic acoustic transducer comprising a magnet and a coil is located in the interior space of the socket near the bolt. The coil induces eddy currents while the magnet provides a magnetic field such that the magnet and the coil together generate an ultrasonic signal directly into the bolt. A detector is used to detect and measure a change in the transit time of the ultrasonic signal in the bolt. The device thus continuously measures and controls load on the part during a torquing fastening operation and provides a continuous monitoring of the part's integrity by detecting cracks or flaws prior to initiation of and/or during the loading procedure. The invention will now be described by way of example with reference to the accompanying drawings, throughout which like parts are referred to by like references, and in which: Fig. 1 is a schematic view illustrating an embodiment of the present invention; Fig. 2 is a schematic view illustrating the device of Fig. 1 used in conjunction with a detector and a monitor; Fig. 3 is a schematic view illustrating a bolt tension test set-up; Fig. 4 is a graph plotting a change in transit time versus bolt load; Fig. 5 is a cross-section of a defect-free fastener with an EMAT illustrating the path of an ultrasonic wave; Fig. 6 is an EMAT display showing the defect-free fastener; Fig. 7 is a cross-section of a flawed fastener with an EMAT illustrating the path of an ultrasonic wave; and Fig. 8 is an EMAT display showing reflections from the crack in the fastener shown in Fig. 7. There will now be described a device and method for tension and load measurement of a bolt using an electromagnetic acoustic transducer. The present technique in conjunction with the tension and load measurement of the fastener also provides a continuous monitor of fastener integrity by detecting cracks or flaws prior to the initiation of and during the loading procedure. Further, the present technique may be employed to verify that the proper fastener material including the right alloy and heat treatment condition has been employed in a particular application. The present device comprises an electromagnetic acoustic transducer (EMAT) which generates and receives ultrasonic waves without the need to contact the material of a part such as a fastener like a bolt, in which the ultrasonic waves travel. The device embodying the present invention, as shown in Fig. 1, is used in conjunction with a bolt 2 and comprises a socket 15 having an interior space 17. The socket 15 engages the bolt 2 for tensioning the bolt 2 and placing a load thereon. The interior space 17 of the socket 15 is located between the bolt 2 and the socket 15. A socket drive 10 is used in conjunction with the socket 15; the socket drive 10 is detachably engageable with the socket 15 for changing to different size sockets so as to accommodate different sized bolts 2. An electromagnetic acoustic transducer (EMAT) assembly 20 is located within the interior space 17 of the socket 15 at the bolt 2. The EMAT assembly 20 comprises a housing 22 and a wearplate 24 which contacts the bolt 2. Within the housing 22 and the wearplate 24 is located a permanent magnet 28 for producing a magnetic field and a coil 26 for providing a current. The EMAT assembly 20 is connected to the socket drive 10 by attachment bolts 21 and springs 23. A cable 27 is connected to the coil 26 for providing the current to the coil 26. The cable 27 is channelled to the coil 26 through a cable routing hole 12 located within the socket drive 10. The cable 27 is connected to the socket drive 10 by a slip ring assembly 30 engaged around the socket drive 10. The slip ring assembly 30 comprises slip ring brushes 32. The electromagnetic transducer assembly 20 is used as a generator of ultrasonic waves by locating the coil 26 in a uniform magnetic field produced by the permanent magnet 28 (or an electromagnet) such that the ultrasonic waves are provided near the surface of the metal bolt 2. By transformer action, a surface current is introduced into the metal bolt 2. This surface current in the presence of the magnetic field experiences a Lorentz force which produces oscillating surface stresses. On reception, the surface of the metal 2 oscillates in the magnetic field thereby inducing a voltage in the coil 26. The transduction process takes place within an electromagnetic skin depth, which for materials such as steel or aluminium, at megahertz frequencies, is a fraction of a mil (about 2.5 x 10 -2 mm). An alternative mechanism generally employed with EMATs to generate and receive the ultrasound is magnetostriction. The magnetostriction mechanism involves generating and receiving ultrasound in ferromagnetic materials through magnetic interactions. When a magnetic field is applied to a ferromagnetic material, the material experiences an internal stress. This process is known as magnetostriction. The amount of stress generated depends on the magnitude of the magnetic field and the properties of the material. EMATs are employed for ferromagnetic materials where a static or quasi-static magnetic field is applied to the ferromagnetic material to bias the material into a region where a small change in magnetic field produces a large change in stress. An RF (radio frequency) coil is then driven with an RF channel burst to set up RF magnetic fields in the surface of the material. The RF fields set up stresses in the material surface which launch ultrasound into the material. Ultrasound is detected by a reciprocal process. With either mechanism, the received signal strength falls off exponentially with increasing gap between the EMAT coil and the metal surface. The present technique provides a very reproducible non-contact system for generating and detecting ultrasound. Since the current of the EMAT coil 26 directly generates ultrasonic waves in the surface of the bolt 2, the precise time of flight measurements can be made by timing from the current pulse to the first reflection which eliminates many of the problems associated with known ultrasonic measuring devices. Due to the development of the present technique, some of the problems that have been associated with previous efforts to measure bolt loading by ultrasonic methods have been minimized or eliminated. The EMAT embodying the present invention generates and receives ultrasonic waves without the need to contact the material in which the waves are travelling. This eliminates the requirement for a liquid couplant between the transducer and the material under test, which is the source of significant error and problems for automating the measurement process. In operation, the EMAT sensor 20 rotates with the socket 15 and the bolt 2. Ultrasonic signals are transmitted and received via the slip rings 32 while testing the bolted joint. Alternatively, the transducer cable 27 may be allowed to twist during the bolt tightening. Fig. 2 shows EMAT instrumentation and computer 25 comprising a display means 60 and a remote amp and matching network 29 which electrically matches the EMAT coil 26 and cable 27 to the EMAT instrumentation 25. The detector within the EMAT instrumentation 25 is a computer which takes measurements on the unloaded bolt 2 in order to establish a base line, and then measures and plots the bolt load while tightening the bolt 2. As shown in Fig. 1, the EMAT sensor 20 is spring loaded by springs 23 so that the sensor 20 is automatically seated on the head of a bolt 2 as soon as the socket 15 is placed on the bolt head 2. The EMAT sensor 20 is attached to the drive assembly 10 in such a manner so that several different bolt sizes can be accommodated by changing sockets 15. EMAT measurements are taken as follows, initially prior to loading, i.e. on an unloaded bolt, then continuously during the loading of the bolt, and finally after the loading of the bolt. When the desired load has been reached, the sensor 20 does not have to be removed. This eliminates the errors previously encountered in known transducers which are caused by having to attach and remove the ultrasonic transducers for the two tests, i.e. the preload test and the postload test. The present method is well suited for automotive bolt tightening for use in production lines and various robotic applications. It is well known that commercial ultrasonic bolt load measurement devices have been found to produce highly variable results primarily due to couplant variability. Additionally, the repeatability of the present EMAT method for measurements spaced over a period of time is much better than that of conventional ultrasonic methods. It may be desirable to measure the load of a bolt periodically to ensure that it is still within specifications. Because the EMAT 20 operates without couplant, re-application of the sensor 20 to make periodic measurements produces results with good accuracy if the load is unchanged. A preliminary study of using an EMAT for measuring bolt loading was first conducted under laboratory conditions. Fig. 3 shows an experimental set-up used during the preliminary study. A tension test set-up 40 was used in conjunction with a bolt loading fixture 4 and 6 and a 50,000 pound (about 250,000 N) loading frame comprising a load device 45. A specimem bolt 2 was loaded in the tension set-up 40 at 5,000 pound (about 25,000 N) increments and measurements of arrival time, load cell output, from load cell 47, and bolt temperature were recorded. The results of the measuring times for the transmitter current pulse to first echo are illustrated in Fig. 4 for two successive load cycles. The effect on the accuracy of the readings caused by removing and replacing the transducer was tested by removing and replacing the transducer on the head of the unstressed bolt six times. The maximum variation in the time of flight was 4 ns or an error corresponding to about 1.5% of the recommended load value. The average variation was only 1.2 ns or less than 0.5% of the applied load. These results were unexpected since the experimental transducer was not very rugged, and indicate that the transducer can be easily removed and replaced without introducing significant errors in bolt preload measurements. The ability to remove and replace the transducer without introducing significant errors allows for the reloading of a bolt in an assembly where preload can change. Figs. 5 to 8 show the manner in which the EMAT assembly 20 located within the socket (not shown) can also be used to provide a continuous monitor of fastener integrity by detecting cracks or flaws prior to the initiation of and during the loading procedure. Furthermore, the EMAT assembly 20 can also be employed to verify that the proper fastener material, alloy and heat treatment condition is being used for a particular application. These material properties influence ultrasonic velocity/attenuation. The fastener material may be verified as soon as the sensor assembly 20 is positioned on the fastener or bolt 2 prior to load monitoring. The term "fastener" as used herein is meant to include a bolt, a screw, a rivet, or any other fastener. In Figs. 5 to 8, there is shown an EMAT generated ultrasonic wave and the manner in which it propagates through a defect-free fastener in Fig. 5 and a flawed fastener in Fig. 7. Since EMAT ultrasonic generation is so material dependent (electrical resistivity, magnetic permeability, density, etc.) the placement of the EMAT on the surface of the fastener will provide immediate verification that each fastener is correct in terms of material, alloy and heat treatment. After EMAT placement and material verification, if the ultrasound wave strikes an object in the form of a crack or inhomogeneity, part of the energy will (depending on the size and orientation of the flaw or reflector) be reflected back to the receiver of the EMAT assembly 20 and the remainder will travel further into the fastener 2 eventually reflecting off the back wall or end of the fastener. Fig. 7 illustrates this for a crack 3. The signals from the receiver of the EMAT assembly 20 are displayed as peaks on a base line of the cathode ray tube display as shown in Figs. 6 and 8 for a defect-free and flawed fastener respectively. The horizontal sweep of the display is proportional to time so the transit times of the ultrasonic wave to and from the flaw or reflector, and to and from the back wall correspond respectively to the distances on the screen from the initial peak to the echo peak corresponding to the reflector and back wall. By calibration of the display instrument time base in time per unit length, the transit time to the end of the fastener can be clearly shown, and any crack or other flaw will act as a reflector and cause an echo or indication on the EMAT display located between the initial pulse and the back wall (bolt end). An advantage of the present technique is that the EMAT assembly is used to measure and/or control simultaneously the loading or tightening operation, confirm and monitor integrity by detecting flaws to eliminate using a defective bolt in production as well as verify material, alloy, and heat treatment condition by the simple step of placing the fastening device on the fastener.

Claims: A device operable to verify material, alloy and heat treatment condition of a part immediately prior to loading and operable to measure a load on the part and continuously to monitor the integrity of the part before, during and after loading the part, the device comprising: means (15) operable to engage the part (2), said engaging means (15) having an interior space (17) between the engaging means (15) and the part (2); drive means (10) operable to transmit a load to the part (2) through said engaging means (15), said drive means (10) being detachably engageable with said engaging means (15); a coil (26) located in the interior space (17) near the part (2) and operable to introduce an eddy current in the part (2); means (27) operable to provide current to said coil (26); a magnet (28) engaging the coil (26) in the interior space (17) and being attached to said drive means (10) thereby to provide a magnetic field, the magnet (28) and the coil (26) generating a noncontact ultrasonic signal in the part (2); detection means (25) operable to detect a change in the ultrasonic signal provided to the part (2); and display means (60) responsive to the detection means (25) to show any change in the ultrasonic signal indicative of a flaw in the part (2), wherein said display means (60) in use is operable to compare the ultrasonic signal with a calibrated signal to verify material, alloy and heat condition treatment. A device according to claim 1, wherein said engaging means comprises a socket (15). A device according to claim 1 or claim 2, including a housing (22) located in the interior space (17) and a wearplate (24) for contacting the part (2), the coil (26) and the magnet (28) being connected to the housing (22), and connecting means (21) for connecting the housing (22) to the drive means (10). A device according to claim 3, wherein the connecting means comprises a bolt (21) connected to the housing (22) and the drive means (10). A device according to claim 4, wherein the connecting means further comprises a spring (23) between the housing (22) and the drive means (10). A device according to any one of the preceding claims, including a cable (27) connected to the coil (26) and the detection means (25). A device according to claim 6, wherein the drive means (10) includes an aperture (12) for channelling the cable (27) to the coil (26). A device according to claim 6 or claim 7, including retaining means (30) for electrically connecting the cable (27) to the coil (26). A device according to claim 8, wherein the retaining means comprises a slip ring assembly (30) engaged with the drive means (10). A method of verifying material, alloy and heat treatment condition of a part immediately prior to loading and of measuring a load on the part and continuously monitoring the integrity of the part before, during and after loading the part, the method comprising the steps of: engaging the part (2) with an engaging means (15) such that an interior space (17) is provided between the engaging means (15) and the part (2); transmitting a load to the part (2) with drive means (10) through the engaging means (15), the drive means (10) being detachably engageable with the engaging means (15); attaching a magnet (28) with a coil (26) to the drive means (10) so that the magnet and coil (26) are positioned in the interior space (17) of the engaging means (15); generating a magnetic field in the interior space (17) of the engaging means (15); providing a current in the interior space (17) such that the current and the magnetic field produce a noncontact ultrasonic signal in the part (2); monitoring the ultrasonic signal in the part (2); detecting (25) a change in the ultrasonic signal; displaying (60) any detected change in the ultrasonic signal indicative of a flaw in the part (2); and comparing the ultrasonic signal with a calibrated signal for verifying material, alloy and heat treatment condition for the part (2). A method according to claim 10, wherein the engaging means comprises a socket (15). A method according to claim 10 or claim 11, including rotating the engaging means (15) and the part (2).

Inventors: CLARK STEVEN P, LATHAM WAYNE M, MACLAUCHLAN DANIEL T, CLARK,STEVEN P., LATHAM,WAYNE M., MACLAUCHLAN,DANIEL T.
Applicants: MCDERMOTT TECHNOLOGY INC, MCDERMOTT TECHNOLOGY, INC.
Application year: 1997
Main classification: G01L5
IPC codes: G01N29, G01H11, G01L5, G01L1, G01M13, F16B31