Understanding the amount of degradation using nondestructive evaluation (NDE) methods provides an effective way of determining the fitness to service and the residual life of structural components. Due to uncertainties introduced by the single NDE method, a combined damage index using multi-sensor data increases the reliability of damage assessment. In this paper, the outputs of three NDE methods including acoustic emission (AE), linear ultrasonics (LUT), and nonlinear ultrasonics (NLUT) are merged to identify the amount of plastic deformation in aluminum 1100. The sensitivities of individual and combined methods to microstructural changes are evaluated. The coupon samples are loaded up to different strain levels and then unloaded. AE data is recorded in real time and ultrasonic data is recorded from the unloaded samples. The major features combined in the damage index are cumulative AE absolute energy and nonlinear coefficient. The microstructural state is verified with microscopic analysis and hardness testing. The developed damage index can nondestructively assess the amount of plastic deformation with higher reliability.
Keywords: acoustic emission; combined NDT method; failure mechanism; linear ultrasonic testing; nonlinear ultrasonic testing.