This work focuses on non-destructive examinations using array probe ultrasonic waves on complex materials generating a high structural noise on the examined area. During an ultrasonic examination, multiple scattering of the ultrasonic waves at the grain boundaries makes the distinction between this structurally induced noise and a potential defect challenging. The difficulty of the interpretation can moreover be increased in the near surface area because of the subsurface wave. In order to ease the analysis of these acquisitions, some numerical processing methods are proposed. Statistical properties of the imaging results (for instance, total focusing method or plane wave imaging) are first calculated on several sensor positions. These statistical properties are then used to post-process the imaging results and enhance any signal values that do not belong to the structural noise expected statistics. The method, called “CORUS,” has been successfully tested on cast austenoferritic stainless steel coarse-grained mock-ups, with several dB gain compared to the classical total focusing method. It is now integrated in a civa software plugin and in a prototype version of the real-time PANTHER-phased-array acquisition system from Eddyfi Technologies.

In a reliability assessment of ultrasonic time-of-flight diffraction (TOFD) inspection, probability of detection (POD) and sizing (POS) curves are developed. Experiments are performed on a complex geometry specimen with the grooved inspection surface simulating the gland seal area of a steam turbine rotor. In the reliability experiment, it is assumed and confirmed that the distribution of signal responses is normal. The effects of probe center spacing on detection and sizing are observed. The PODs developed here have a decreasing trend with flaw size which is in contrary to the generally observed increasing trend in conventional ultrasonic amplitude-based flaw sizing techniques. The reason for this decreasing POD with crack height is explained in the present study. The curves developed in this work are specific to the geometry and dimensions of the specimen with the set of notches and the probes used in the experiment. Hence, these curves can only be used under similar conditions. In TOFD inspection of similar type of complex shaped structures, e.g., turbine, the POD and POS curves developed here can be used in taking an appropriate engineering decision with respect to run, repair, or replace.

Corrosion of carbon steel rebar in concrete structures, such as highway bridges and buildings, has a direct impact on their structural integrity since the rebar provides the tensile strength within the structure. Rebar strength depends on the remaining effective radius of a given rod. Long-time decay up to 0.1 s, in the transient response of pulsed eddy current (PEC), was examined as a potential method to quantify general corrosion in ferromagnetic rebar. The transient response of a coaxial solenoidal drive–receive coil pair, oriented parallel to the rebar axis, was analyzed over a range of distances into the concrete (liftoff) and rebar radii. At long times, the single exponential decay constant was largely independent of liftoff. A power law relationship for the characteristic decay time, consistent with long-time diffusion of electromagnetic fields into a rod, was observed. The intercept of a best-fit line to measured voltage decay decreased exponentially with liftoff and maintained a measurable response up to 110 mm distance for a 25 mm (1 in.) diameter rebar. This exponential decay was present in 22 mm (7/8 in.), 19 mm (3/4 in.), and 15 mm (5/8 in.) samples as well. Reported results demonstrate the potential for PEC to quantify remaining cross-sectional area of rebar in concrete structures.

A validated analytical model of a transmit–receive coil pair situated above two parallel plates, separated by an air gap, was used as the basis for an inversion algorithm (IA) to extract probe liftoff, second layer plate resistivity, and plate-to-plate gap from multi-frequency eddy current data. The IA was tested over a large range of first layer wall thickness (3.80–4.64 mm), second layer plate resistivity (1.7–174 µΩ cm), second layer wall thickness (1.20–4.85 mm), probe liftoff (2.8–7.9 mm), and plate-to-plate gap (0–13.3 mm). At nominal liftoff (2.8 mm), the IA achieved a gap measurement accuracy of ±0.7 mm and was able to return good estimates of the second layer resistivity within ±1 μΩ cm for low resistivity samples, but with decreasing accuracy for higher resistivities. When the gap was fixed, the IA was able to measure changes in probe liftoff (relative to nominal) to an accuracy of ±0.2 mm. The reported accuracy and a demonstration for the ability to accurately estimate parameters outside of the calibration range provide confidence in the potential utility of the algorithm.

Nonlinear ultrasonic (NLU) techniques have emerged as a potential solution to improve the resolution of nondestructive measurements to detect microstructural changes of cyclically loaded materials. However, current NLU methods need power-demanding instrumentation that is useful only in the laboratory settings. On the other hand, phased array systems provide the capability of sensing such changes when the later portion of the elastic waveforms, called diffuse field, is analyzed. Moreover, phased array systems are an excellent solution for field test measurement and imaging of material damage. This study explores the use of NLU metrics based on ratios of harmonic amplitudes and frequencies to map the buildup of damage precursors, such as crystal dislocations, under cyclic loading within the microstructure of fatigued 2024-T3 aluminum specimens. The results show that these metrics are highly sensitive to microstructural fatigue damage making them significantly important to measure mechanical properties, such as fracture toughness, that are extremely useful in predicting the remaining useful life of a studied material. A nonlinear metric of elastic energy that encapsulates the nonlinear effects of subharmonic and higher-harmonic generations and frequency ratio is proposed. These effects of spectral energy shifts are combined making this metric highly sensitive to nano- and micro-scale damage within the fatigued medium.

Thickness measurements using an ultrasonic contact test is a well-known nondestructive evaluation technique. However, its implementation in a robotic system with a closed-loop feedback control for artificial intelligent measurements requires precise information of positioning and force of the ultrasonic probe. In this work, we describe an ultrasonic probe developed in our lab that uses a semispherical soft membrane made from an elastomer. The aim is to develop a methodology for precise positioning and force control of a dry contact ultrasonic probe based on the ultrasonic signal information processed using sparse matrix optimization and Fourier analysis techniques. The results show that the proposed methodology makes easy to achieve a fine tuning of the probe orientation with high sensitivity to load and misalignment in order to perform accurate thickness measurements.

The use of eddy current (EC) arrays to detect damage in sandwich panels, such as disbonding of the carbon fiber reinforced polymer (CFRP) face-sheet to the core, is investigated. It is shown that the array is very sensitive to slight core crush and can readily find small dents and disbonds. At the same time, the eddy current array can look much deeper into the honeycomb to detect defects such as tears. The phase map of the EC signal can be used in some cases to distinguish between different types of damage. EC arrays offer the ability to rapidly scan large areas of CFRP panels.

A system consisting of a multiplexer and multiple ultrasonic probes was developed for in situ monitoring of the water condensation height in steam pipes under steady-state and turbulent flow conditions. The measurement method, the signal processing techniques, the experimental setup, and the test results are presented in this paper. The feasibility and efficiency of the developed multitransducers and signal processing algorithms were demonstrated. The measured water height and wave pattern in dynamic surface conditions inside the pipe were verified through the snapshot of the recorded video images. The developed methodology built the framework for the use of multiple transducers array ultrasonic system for practical application to in situ monitor the water height in steam pipes.