Modelling and simulation of novel optoacoustic sensors for monitoring crack growth in pressure vessel steels

The acoustic emission technique is an effective way to acquire crack information from material bodies at the microscopic level. Monitoring of the acoustic emission events provides a deeper understanding regarding the structural health status of critical constructions such as bridges, railways, pipelines, pressure vessels, etc. Thanks to the acoustic emission monitoring systems, it is possible to avoid catastrophic events and save lives, time, and money. For this reason, efforts to develop new acoustic emission sensor technologies, as well as the use of current acoustic emission sensors in new research fields, will contribute to the limited literature sources. Optical sensing systems provide good alternatives to the existing sensing technologies because of their wide range of detection bandwidths, adaptation to harsh environments, and low sensitivity to electromagnetic interference. For this reason, the first part of this thesis demonstrates an optoacoustic sensing methodology that enables the detection of acoustic emissions by optics. This sensing system consists of thin-film optical filters (TFOF) and an elastic microcavity layer. The sensing mechanism is similar to the Fabry Perot structures and it relies on resonance shifts of the cavity when there is a change in the cavity thickness similar to the Fabry Perot structures. Thus, the design, fabrication, and demonstration steps of a Fabry Perot elastic microcavity have been presented. Throughout the fabrication efforts, a new deposition protocol was developed. This deposition technique has enabled the deposition of TFOF on flexible substrates via the RF-sputtering technique. Thus, a new sensing configuration has been developed using flexible optical components. In the second chapter, an optical sensing methodology based on tunable spectral filters and flexible optical components is introduced. The design, fabrication, realization, and characterization of a proof-of-concept optomechanical sensor have been presented. The design step includes optical, mechanical, and optoacoustic correlation simulations using the Transfer Matrix Method, finite element analysis, and analytical models. Moreover, the fabrication part includes multilayer deposition on silica and flexible substrates using the RF-Sputtering technique and integration of these optical components into a 3D-printed housing together with electronic components. Eventually, the performance evaluation of the optomechanical sensor has been carried out and the experimental results showed that the sensor resonance frequency is around 515 Hz and the sensor is capable of detecting static loadings from 50 Pa to 235 Pa values. In the fourth chapter, seismic vulnerability analysis of a coupled Tank-Piping System has been performed using traditional acoustic emission sensors. Real-time performance evaluation of the pipeline as well as the structural health status of the critical parts were monitored. As a result, deformation levels of each critical part were investigated, and the processing of acoustic emission signals provided a more in-depth view of damage level of the analyzed components. Throughout the thesis, TFOFs are an integral part of this thesis. Therefore, both the design and simulation of TFOFs play a crucial role throughout this research work. The Transfer Matrix Method is used to simulate the optical performance of TFOFs. Moreover, in the final chapter, an automated design framework is presented for the design of TFOFs using a nature-inspired machine learning approach called Genetic algorithm. This design approach enables the design of sophisticated geometric configurations with unique optical capabilities. Therefore, not only the improvement of sensor response but also the new ways in the development of novel optical systems are demonstrated in this final chapter.