Stereo high-speed video of photovoltaic modules undergoing laboratory hail tests was processed using digital image correlation to determine module surface deformation during and immediately following impact. The purpose of this work was to demonstrate a methodology for characterizing module impact response differences as a function of construction and incident hail parameters. Video capture and digital image analysis were able to capture out-of-plane module deformation to a resolution of ±0.1 mm at 11 kHz on an in-plane grid of 10 × 10 mm over the area of a 1 × 2 m commercial photovoltaic module. With lighting and optical adjustments, the technique was adaptable to arbitrary module designs, including size, backsheet color, and cell interconnection. Impacts were observed to produce an initially localized dimple in the glass surface, with peak deflection proportional to the square root of incident energy. Subsequent deformation propagation and dissipation were also captured, along with behavior for instances when the module glass fractured. Natural frequencies of the module were identifiable by analyzing module oscillations postimpact. Limitations of the measurement technique were that the impacting ice ball obscured the data field immediately surrounding the point of contact, and both ice and glass fracture events occurred within 100 μs, which was not resolvable at the chosen frame rate. Increasing the frame rate and visualizing the back surface of the impact could be applied to avoid these issues. Applications for these data include validating computational models for hail impacts, identifying the natural frequencies of a module, and identifying damage initiation mechanisms.
High-speed, optical imaging diagnostics are presented for three-dimensional (3D) quantification of explosively driven metal fragmentation. At early times after detonation, Digital Image Correlation (DIC) provides non-contact measures of 3D case velocities, strains, and strain rates, while a proposed stereo imaging configuration quantifies in-flight fragment masses and velocities at later times. Experiments are performed using commercially obtained RP-80 detonators from Teledyne RISI, which are shown to create a reproducible fragment field at the benchtop scale. DIC measurements are compared with 3D simulations, which have been ‘leveled’ to match the spatial resolution of DIC. Results demonstrate improved ability to identify predicted quantities-of-interest that fall outside of measurement uncertainty and shot-to-shot variability. Similarly, video measures of fragment trajectories and masses allow rapid experimental repetition and provide correlated fragment size-velocity measurements. Measured and simulated fragment mass distributions are shown to agree within confidence bounds, while some statistically meaningful differences are observed between the measured and predicted conditionally averaged fragment velocities. Together these techniques demonstrate new opportunities to improve future model validation.
Residual stress is a contributor to stress corrosion cracking (SCC) and a common byproduct of additive manufacturing (AM). Here the relationship between residual stress and SCC susceptibility in laser powder bed fusion AM 316L stainless steel was studied through immersion in saturated boiling magnesium chloride per ASTM G36-94. The residual stress was varied by changing the sample height for the as-built condition and additionally by heat treatments at 600°C, 800°C, and 1,200°C to control, and in some cases reduce, residual stress. In general, all samples in the as-built condition showed susceptibility to SCC with the thinner, lower residual stress samples showing shallower cracks and crack propagation occurring perpendicular to melt tracks due to local residual stress fields. The heat-treated samples showed a reduction in residual stress for the 800°C and 1,200°C samples. Both were free of cracks after >300 h of immersion in MgCl2, while the 600°C sample showed similar cracking to their as-built counterpart. Geometrically necessary dislocation (GND) density analysis indicates that the dislocation density may play a major role in the SCC susceptibility.
Phase-based motion processing and the associated Motion Magnification that it enables has become popular not only for the striking videos that it can produce of traditionally stiff structures visualized with very large deflections, but also for its ability to pull information out of the noise floor of images so that they can be processed with more traditional optical techniques such as digital image correlation or feature tracking. While the majority of papers in the literature have utilized the Phase-based Image Processing approach as a pre-processor for more quantitative analyses, the technique itself can be used directly to extract modal parameters from an image, noting that the extracted phases are proportional to displacements in the image. Once phases are extracted, they can be fit using traditional experimental modal analysis techniques. This produces a mode “shape” where the degrees of freedom are phases instead of physical motions. These phases can be scaled to produce on-image visualizations of the mode shapes, rather than operational shapes produced by bandpass filtering. Modal filtering techniques can also be used to visualize motions from an environment on an image using the modal phases as a basis for the expansion.
This work explores the effect of the ill-posed problem on uncertainty quantification for motion estimation using digital image correlation (DIC) (Sutton et al. [2009]). We develop a correction factor for standard uncertainty estimates based on the cosine of the angle between the true motion and the image gradients, in an integral sense over a subregion of the image. This correction factor accounts for variability in the DIC solution previously unaccounted for when considering only image noise, interpolation bias, contrast, and the software settings such as subset size and spacing.
We develop a generalized stress inversion technique (or the generalized inversion method) capable of recovering stresses in linear elastic bodies subjected to arbitrary cuts. Specifically, given a set of displacement measurements found experimentally from digital image correlation (DIC), we formulate a stress estimation inverse problem as a partial differential equation-constrained optimization problem. We use gradient-based optimization methods, and we accordingly derive the necessary gradient and Hessian information in a matrix-free form to allow for parallel, large-scale operations. By using a combination of finite elements, DIC, and a matrix-free optimization framework, the generalized inversion method can be used on any arbitrary geometry, provided that the DIC camera can view a sufficient part of the surface. We present numerical simulations and experiments, and we demonstrate that the generalized inversion method can be applied to estimate residual stress.