Tag Archives: engines

Thinking out of the box leads to digital image correlation through space

This is the third in a short series of posts on recent engineering research published by my research group.  Actually, two have already been published: ‘Salt increases nanoparticle diffusion‘ on April 22nd, 2020; and ‘Spatio-temporal damage maps for composite materials‘ on May 6th, 2020 and then I got distracted.  This third one arose from the same project as the time-damage maps which was sponsored by the United States Air Force.  The time-damage maps allow us to explore the evolution of failure in complex materials; however, we already know that damage tends to initiate from imperfections or flaws in the microstructure in the material.  New continuous fibre reinforced composite (CFRC) materials based on ceramics are very sensitive to defects or anomalies in their microstructure, such as misalignment of fibres.  However, they are capable of withstanding temperatures in excess of 1500 degrees Centigrade, which offers the opportunity to use them in jet engines or nuclear power plants to help generate energy more efficiently.  Therefore, it is worthwhile investigating effective methods of inspecting their microstructure which we can do either destructively by repetitively polishing away the surface of a sample and viewing it in a microscope, or non-destructively using x-ray tomography.  In both cases, the result is hundreds of ‘images’ containing millions of data values from which it is challenging to extract useful information.  In our work, we have used a little lateral thinking, to show how digital image correlation, usually used to track deformation of structures using multiple images collected over time [see ‘256 shades of grey‘ on January 22nd, 2014] , can be used to track fibres through the multiple images of the layers of the microstructure.  The result is the sort of ‘stick’ diagram in the image showing the orientation of fibres through the sample.  We have demonstrated that our new algorithm was more reliable and 30 times faster than its nearest rival.

The image shows, at the top, a typical stack of images from the microscope of a ceramic matrix composite; and, at the bottom, a plot of 3d profiles of the fibres tracked using the DIC-based method with the fibres orientated nominally at ±45° from the sectioning (x-y) plane shown in red and green colours.

Source:

Amjad K, Christian WJR, Dvurecenska K, Chapman MG, Uchic MD, Przybyla CP & Patterson EA, Computationally efficient method of tracking fibres in composite materials using digital image correlation, Composites Part A, 129:105683, 2020.

 

Aircraft inspection

A few months I took this series of photographs while waiting to board a trans-Atlantic flight home.  First, a small ladder was placed in front of the engine.  Then a technician arrived, climbed onto the ladder and spread a blanket on the cowling before kneeling on it and spinning the fan blades slowly.  He must have spotted something that concerned him because he climbed in, lay on the blanket and made a closer inspection.  Then he climbed down, rolled up the blanket and left.  A few minutes later he returned with a colleague, laid out the blanket and they both had a careful look inside the engine, after which they climbed down, rolled up the blanket put it back in a special bag and left.  Five or ten minutes later, they were back with a third colleague.  The blanket was laid out again, the engine inspected by two of them at once and a three-way discussion ensued.  The result was that our flight was postponed while the airline produced a new plane for us.

Throughout this process it appeared that the most sophisticated inspection equipment used was the human eye and a mobile phone.  I suspect that the earlier inspections were reported by phone to the supervisor who came to look for himself before making the decision.  One of the goals of our current research is to develop easy-to-use instrumentation that could be used to provide more information about the structural integrity of components in this type of situation.  In the INSTRUCTIVE project we are investigating the use of low-cost infra-red cameras to identify incipient damage in aerospace structures.  Our vision is that the sort of inspection described above could be performed using an infra-red camera that would provide detailed data about the condition of the structure.  This data would update a digital twin that, in turn, would provide a prognosis for the structure.  The motivation is to improve safety and reduce operating costs by accurate identification of critical damage.

 

Engineering is all about ingenuity

Painting from Okemos High School Art Collection at MSU

Painting from Okemos High School Art Collection at MSU

Who was the first engineer?  It’s a tricky question to answer.  Some sources cite Ailnolth, who lived in the second half of the twelfth century and worked on the Tower of London, as one of the first to be called an ‘ingeniator’.  The word comes from the Latin and the Roman writer, Vitruvius, describes master builders as being ingenious or possessing ‘ingenium’.  Leonardo da Vinci (1452 – 1519) was perhaps the first person to be appointed as an engineer.  The Duke of Milan appointed him ‘Ingenarius Ducalis’ or Master of Ingenious Devices.

So it would appear that an engineer is ‘a skilful contriver or originator of something’,  which is the third definition in the on-line Oxford Dictionary after ‘a person who designs, builds, or maintains engines, machines or structures’ and ‘a person who controls an engine especially on an aircraft or ship’.  This type of engine, which uses heat to do work, is a relatively recent invention probably by Thomas Savery and Thomas Newcomen in the early eighteenth century.  Engineers have been contriving, designing and inventing ‘works of public utility’ [quote from my older hard copy Oxford English Dictionary] for many centuries before the heat engine hijacked the terminology.

Why does this matter?  Well, many people have a misconception that engineering is all about engines, the heat kind; and yes, some of us do design, build and maintain engines but very many more engineers contrive, design and invent works of public utility – in the broadest sense of the words, i.e. just about everything ‘invented’ in the world. In other words, engineering is using human ingenuity to produce something useful; preferably something that improves the quality of life – oh, but now we are moving into ethics and I will leave that for another day!

Sources:

Blockley D, Engineering: A Very Short Introduction, Oxford: Oxford University Press, 2012.

Auyang SY, Engineering – an endless frontier, Cambridge MA: Harvard University Press, 2004.

Little W, Fowler HW & Coulson J, The Shorter Oxford English Dictionary, C.T. Onions (editor), London: Guild Publishing, 1983.

 

And then we discovered thermodynamics

sunEnergy, matter, space and time came into existence in the Big Bang 13.5 billion years ago. 10 billion years later biological organisms started to appear. 70,000 years ago one of those organisms, man started to organise in structures, called cultures and history began. For most of history if you wanted something moved then you had to do it yourself or persuade someone else to do it. The agricultural revolution began 12,000 years ago and shortly afterwards we realised that if you fed fuel to an animal then it would ‘burn’ it and do work for you. And that’s how it remained for thousands of years – we didn’t know how to convert heat into work or work into heat. The average energy consumption per capita was about 20GJ per year. Then, 200 years ago we discovered how to imitate nature by burning fuel and producing power in the steam engine. We had discovered thermodynamics and our average energy consumption started rising towards 80GJ per year today.

As a consequence, ‘we have now all but destroyed this once salubrious planet as a life-support system in fewer than two hundred years, mainly by making thermodynamic whoopee with fossil fuels’ as Kurt Vonnegut wrote. And that’s because nature starts from solar energy and recycles everything and we haven’t learnt how to do either very effectively. But energy or power engineering has been around for less than a blink of eye relatively speaking and we are just learning how to perform a trick nature has been using for billions of years: convert solar radiation into other energy forms. The sun delivers about 340 Watts per square metre to the Earth so we have plenty energy available.

If you would like to know more about energy engineering or thermodynamics and its potential then join the 5000 people who have signed up for the MOOC that I am teaching for five weeks from next Monday.  Listen to me interview Ken Durose, Director of the Stephenson Institute for Renewable Energy on the prospects for renewable energy.

Sources:

http://ourfiniteworld.com/2012/03/12/world-energy-consumption-since-1820-in-charts/

Yuval Noah Harari, Sapiens: A brief history of mankind. London: Vintage (Penguin, Random House), 2014.

Kurt Vonnegut, A Man without a Country, New York: Seven Stories Press, 2005.