Ultrasonic non-destructive testing traditionally uses a conventional monolithic transducer. An approach similar to this comprising of independent single transmissions but with reception performed by all the elements in phased array ultrasonics is known as Full Matrix Capture (FMC). The acquired data is processed by Total Focusing Method (TFM). Conventional FMC-TFM has limitations in the inspection at large depth in attenuating materials due to single element transmission. To improve the beam forming process, coherent recombination of the plane wave with specific angles is utilized in transmission and the same aperture is used for the reception in Plane Wave Imaging (PWI). A new methodology called Angle Beam Virtual Source FMC-TFM (ABVSFMC-TFM) is proposed to inspect thick attenuating materials such as nickel base alloys. The ABVSFMC method leads to improved Signal to Noise Ratio (SNR) as compared to the conventional FMC due to increased energy with directivity during transmission using a group of elements and improved divergence as compared to the PWI due to a small virtual source near the sample surface. In the present paper, FMC-TFM, PWI-TFM and ABVSFMC-TFM methods are compared for inspection of thick nickel base superalloy (Alloy 617) with slots at various depths in the range of 25-200 mm. Optimization of the incidence angle has been performed by beam computation in CIVA software. Results obtained by CIVA simulations are discussed and also compared for the three methods.

A guided wave-based structural health monitoring (GW-SHM) system aims at determining the integrity of a wide variety of plate-like structures such as aircraft fuselages, pipes, and fuel tanks. It is often based on a sparse grid of piezoelectric transducers for exciting and sensing GWs that under certain conditions interact with damage while propagating. In recent years, various defect imaging algorithms have been proposed for processing GWs signals and, particularly, for computing an image representing the integrity of the studied structure. The performance of the GW-SHM system highly depends on a signal processing methodology. This paper compares defect localization accuracy of the three state-of-art defect imaging algorithms (delay-and-sum, minimum variance, and excitelet) applied to an extensive simulated database of GWs propagation and GWs-defect interaction in aluminum plate under varying temperature and transducers degradation. This study is conducted in order to provide statistical inferences, essential for SHM system performance demonstration.

X-ray phase contrast imaging (XPCI) is a nondestructive evaluation technique that enables high-contrast detection of low-attenuation materials that are largely transparent in traditional radiography. Extending a grating-based Talbot-Lau XPCI system to three-dimensional imaging with computed tomography (CT) imposes two motion requirements: the analyzer grating must translate transverse to the optical axis to capture image sets for XPCI reconstruction, and the sample must rotate to capture angular data for CT reconstruction. The acquisition algorithm choice determines the order of movement and positioning of the two stages. The choice of the image acquisition algorithm for XPCI CT is instrumental to collecting high fidelity data for reconstruction. We investigate how data acquisition influences XPCI CT by comparing two simple data acquisition algorithms and determine that capturing a full phase-stepping image set for a CT projection before rotating the sample results in higher quality data.

This paper presents a non-contact air-coupled Lamb wave imaging technique using a two-dimensional (2D) cross-correlation method that not only detects the damage but also precisely quantifies for orientations and sizes. The air-coupled transducers (ACT) is used together with a scanning laser Doppler vibrometer (SLDV) for sensing, making a fully non-contact Lamb wave system used for this study. We first show that single-mode Lamb wave actuation can be achieved by the ACT-based on Snell's law. Detailed study and characterization of the directional ACT Lamb waves are conducted. For damage detection, a 2D cross-correlation imaging technique that uses the damage introduced scattered waves of all directions is proposed for correlating with the incident waves. The frequency-wavenumber filtering technique is used to implement the acquisition of the scatted waves and incident waves, respectively. In the end application to notches with various orientations and various sizes in terms of depth and length is given. The results show the proposed technique can precisely imaging the damages and can quantitatively evaluate the damage size in terms of length and depth.

Microtomography is a powerful non-destructive method that allows the visualization of the internal structure of the object and makes possible to generate internal graphic models of the object. Concrete is a mixture widely used in the construction industry due to the union between its mechanical properties with the low cost for its production. The application of X-ray microtomography in lightweight concrete structures allows the visualization of the layout and formation of existing internal structures. In this work, it was possible to identify the presence of ethyl vinyl acetate (EVA) and piaçava fibers in the internal structure of the samples and to classify the high-density aggregates according to the ASTM C125-18 standard, as well as to evaluate the influence of the light aggregates in the increasing of the total porosity.

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.

Steel structures with bolted joints are easily dismantled and repurposed. However, maintaining joint integrity is a challenge. This paper reports a non-destructive methodology to monitor steel bolted joints. Piezoelectric ceramic patches have been surface bonded in the joint for transmission and reception of guided ultrasonic waves. Both single and multiple bolted joints have been investigated. It has been demonstrated that the variation in acoustic impedance due at the bolt interface can be discerned and calibrated with bolt torque level. The recorded reflections from interfaces are used as inputs for a newly developed imaging algorithm. The proposed method has the potential to be a reference-free and fully automated method.

The X-ray computed tomography (XCT) technique is a widely applicable and powerful non-destructive inspection modality for evaluation and analysis of geometrical and physical characteristics of materials, especially internal structures and features. XCT is applicable to metals, ceramics, plastics, and polymer and mixed composites, as well as components and materiel. The Army Research Laboratory (ARL) and its partners are currently investigating the use of cast iron-manganese-aluminum (FeMnAl) steel alloy material in support of weight reduction initiatives in Army Development Programs. Steel alloy FeMnAl has been identified as a key enabling material technology to reduce the weight in ground combat vehicle systems. A set of FeMnAl blocks each approximately 50.8 mm (2 in.) thick by 76.2 mm (3 in.) wide by 76.2 mm (3 in.) long, which had been sectioned from an industrially cast ingot (∼12,000 lbs.), were individually scanned by XCT using a conventional 450 kV X-ray source and a solid-state flat panel detector. Mainly due to the thickness of the blocks, as well as a desire to keep geometric unsharpness relatively small which affected overall scan geometry (set up), the scans had a very low response at the detector through the FeMnAl blocks. With the calibrated detector response through air (i.e., around a block) at 85–90% the response through the block was only 5–10%. The XCT scanning parameters and overall protocol used to mitigate the very low-intensity throughput and achieve acceptable scan image results will be discussed. Image processing (IP) methods used to segment porosity features in the FeMnAl blocks will also be discussed.

When comparing the performance of different industrial X-ray computed tomography (CT) systems, reconstruction algorithms, or scan protocols, it is important to assess how well the required inspection and measurement tasks can be performed. Furthermore, it can be very informative to quantify image quality (IQ) metrics that can provide insight into the IQ characteristics that lead to the resulting inspection or measurement task performance. Inspection and measurement task performance is determined by basic characteristics such as spatial resolution; feature contrast, size, and shape; random noise (noise due to statistical uncertainty in measurements); and image artifacts. In this report, we describe a modular phantom set that enables robustly quantifying these characteristics and also enables assessing the performance of the inspection or measurement tasks themselves. The phantom set includes two phantom bodies and several insert types that can be optionally installed in the bodies. Phantom body extensions can be optionally included to increase scatter. The phantom bodies combined with the available insert types can comprehensively evaluate all important IQ metrics and inspection or measurement tasks. The precisely-known phantom body geometry and insert location, geometry, and orientation supports automatic analysis of large, complex experiments of multiple variables. This phantom set, with the associated image analysis software, could potentially serve as a general evaluation method for non-destructive testing (NDT) CT.

Robust defect detection in the presence of grain noise originating from material microstructures is a challenging yet essential problem in ultrasonic non-destructive evaluation (NDE). In this paper, a novel method is proposed to suppress the gain noise and enhance the defect detection and imaging. The defect echo and grain noise are distinguished through analyzing the spatial location where the echo is originating from. This is achieved by estimation of the angle of arrival (AOA) of the returned echo and evaluation of the likelihood that the echo is reflected from the point where the array is focused or otherwise from the random reflectors like the grain boundaries. The method explicitly addresses the statistical models of the defect echoes and the spatial noise across the array aperture, as well as the correlation between the flaw signal and the interfering echoes; estimates the AOA and the likelihood in a dimension-reduced beam space via a linear transformation; and determines a weighting factor based on the mean likelihood. The factors are then normalized and utilized to correct and weigh the NDE images. Experiments on industrial samples of austenitic stainless steel and INCONEL Alloy 617 are conducted with a 5 MHz transducer array, and the results demonstrate that the grain noise is reduced by about 20 dB while the defect reflection is well retained, thus the great benefits of the method on enhanced defect detection and imaging in ultrasonic NDE are validated.

The manufacturing process of carbon fiber reinforced polymer (CFRP) composite structures can introduce many characteristic defects and flaws such as fiber misorientation, fiber waviness, and wrinkling. Therefore, it becomes increasingly important to detect the presence of these defects at the earliest stages of development. Eddy current testing (ECT) is a nondestructive inspection (NDI) technique that has been proven quite effective in detection of damage in metallic structures. However, NDI of composite structures has mainly relied on other methods such as ultrasonic testing (UT) and X-ray to name a few and not much on ECT. In this paper, the authors explore the possibility of using ECT in NDI of CFRP composites by conducting simulations and experiments thereafter. This research is based on the fact that the CFRP displays some low-level electrical conductivity due to the inherent conductivity of the carbon fibers. This low-level conductivity may permit eddy current pathways to cause the flow of eddy currents in the CFRP composites that can be exploited for nondestructive damage detection. An invention disclosure describing our high-frequency ECT method has also been processed. First, the multiphysics finite element method (FEM) simulation was used to simulate the detection of various types of manufacturing flaws and operational damage in CFRP composites such as fiber misorientation, waviness, wrinkling, and so on. Thereafter, ECT experiments were conducted on CFRP specimens with various manufacturing flaws using the Eddyfi Reddy eddy current array (ECA) system.

Defect quantification is a very important aspect in nondestructive testing (NDT) as it helps in the analysis and prediction of a structure's integrity and lifespan. In this paper, we propose a gradient feature extraction for the quantification of complex defect using topographic primal sketch (TPS) in magnetic flux leakage (MFL) testing. This method uses four excitation patterns so as to obtain MFL images from experiment; a mean image is then produced, assuming it has 80–90% the properties of all four images. A gradient manipulation is then performed on the mean image using a novel least-squares minimization (LSM) approach, for which, pixels with large gradient values (considered as possible defect pixels) are extracted. These pixels are then mapped so as to get the actual defect geometry/shape within the sample. This map is now traced using a TPS for a precise quantification. Results have shown the ability of the method to extract and quantify defects with high precision given its perimeter, area, and depth. This significantly eliminates errors associated with output analysis as results can be clearly seen, interpreted, and understood.

Floating covers are examples of a large membrane structure used at sewage treatment plants. At the Western Treatment Plant (WTP), Werribee, Melbourne, Australia, floating covers are used in the anaerobic lagoons. They are deployed to assist with the anaerobic treatment of the raw sewage beneath, to harness the methane-rich biogas generated, and for odor control. In this respect, these floating covers are important assets for harnessing a sustainable and renewable energy source, as well as protecting the environment from the release of the damaging greenhouse methane-rich biogas from the treatment plant. Given the continuous nature of the biological process beneath the cover, the forces imposed on the floating cover will change with time. Hence, the monitoring and the assessment of the structural integrity of the floating cover are of paramount importance. These floating covers are made from high-density polyethylene (HDPE), a polymeric material. The size of these covers, the hazardous environment, and the expected life span demand a novel, remotely piloted, unmanned aerial vehicle based noncontact technique for the structural health assessment. This assessment methodology will utilize photogrammetry as the basis for determining the surface deformation of the membrane. This paper reports on an experimental study to determine the flight parameters and to assess the accuracy of the measurement technique. It was conducted over an area having similar dimensions to the large covers at the WTP. There are also features in this area, which are of similar scale to those expected in the floating cover. A total of nine test flights were used to investigate the parameters for optimal definition of the significant features to describe the deformation of the floating cover. The findings inform the selection of the unmanned aerial vehicle assisted photogrammetry parameters for optimal flight altitude, photogrammetry image overlap, and flight grid path for future integrity assessment of the floating covers. Two trial flights at WTP are also discussed to demonstrate the effectiveness of this noncontact technique for the future structural health assessment and in assisting with the operation of this large high-value asset.

Peak density is an ultrasound measurement, which has been found to vary according to microstructure, and is defined as the number of local extrema within the resulting power spectrum of an ultrasound measurement. However, the physical factors which influence peak density are not fully understood. This work studies the microstructural characteristics which affect peak density through experimental, computationa,l and analytical means for high-frequency ultrasound of 22–41 MHz. Experiments are conducted using gelatin-based phantoms with glass microsphere scatterers with diameters of 5, 9, 34, and 69 μ m and number densities of 1, 25, 50, 75, and 100 mm −3 . The experiments show the peak density to vary according to the configuration. For example, for phantoms with a number density of 50 mm −3 , the peak density has values of 3, 5, 9, and 12 for each sphere diameter. Finite element simulations are developed and analytical methods are discussed to investigate the underlying physics. Simulated results showed similar trends in the response to microstructure as the experiment. When comparing scattering cross section, peak density was found to vary similarly, implying a correlation between the total scattering and the peak density. Peak density and total scattering increased predominately with increased particle size but increased with scatterer number as well. Simulations comparing glass and polystyrene scatterers showed dependence on the material properties. Twenty-four of the 56 test cases showed peak density to be statistically different between the materials. These values behaved analogously to the scattering cross section.

A computational damage model, which is driven by material, mechanical behavior, and nondestructive evaluation (NDE) data, is presented in this study. To collect material and mechanical behavior damage data, an aerospace grade precipitate-hardened aluminum alloy was mechanically loaded under monotonic conditions inside a scanning electron microscope, while acoustic and optical methods were used to track the damage accumulation process. In addition, to obtain experimental information about damage accumulation at the laboratory scale, a set of cyclic loading experiments was completed using three-point bending specimens made out of the same aluminum alloy and by employing the same nondestructive methods. The ensemble of recorded data for both cases was then used in a postprocessing scheme based on outlier analysis to form damage progression curves, which were subsequently used as custom damage laws in finite element (FE) simulations. Specifically, a plasticity model coupled with stiffness degradation triggered by the experimentally defined damage curves was used in custom subroutines. The results highlight the effect of the data-driven damage model on the simulated mechanical response of the geometries considered and provide an information workflow that is capable of coupling experiments with simulations that can be used for remaining useful life (RUL) estimations.

The increased usage of carbon fiber reinforced plastics (CFRP) for primary aerospace structures involves dealing with the susceptibility of composite laminates to impact loads as well as the occurrence of barely visible impact damages. One special case among impact sources is the so-called blunt impact, which may cause damage primarily to the internal structure. Therefore, the assessment of debonding of stiffening elements in CFRP structures poses an attractive application case for structural health monitoring by guided ultrasonic waves. Wave propagation phenomena at impact damages as well as the signal processing utilized to extract a damage related feature (i.e., damage index (DI)) contribute to the sensitivity, and thus, to the reliability of structural health monitoring (SHM) systems. This work is based on data from the EU-funded project SARISTU, where a generic CFRP door surrounding fuselage panel with an integrated sensor network has been built and tested by introducing a large number of impact damages. Wave interaction of delaminations and stringer debondings of different size and morphology in omega-stringer stiffened structures are examined to highlight the factors contributing to the sensitivity. Common damage indicator formulations for the use with imaging algorithms, such as the reconstruction algorithm for the probabilistic inspection of damage (RAPID), are applied on data from various damage cases. Furthermore, the difference in detectability of delaminations and debondings as well as the implications on imaging algorithms is examined.

Adhesive bonding, an effective joining technique for platelike structures in aircraft and automobiles, requires postbond inspection preferably with noncontact and single-sided access. The present study discusses the application of an imaging technique with a scanning laser source (SLS) to evaluate adhesive bonds in a platelike structure. When a laser Doppler vibrometer (LDV) is used as a receiver, the SLS technique realizes noncontact measurements with single-sided access. The imaging experiments that used narrowband burst waves and broadband chirp waves indicated that the imaging technique is appropriately applied to adhesive bonds and that the use of broadband chirp waves provides clearer images and reduces spurious images due to resonance. Furthermore, images of adhesive bonds were clearly obtained for a complex plate structure that consisted of a top-hat section and a flat plate, and this demonstrates that the imaging technique can be widely applied to evaluate various adhesive bonds.

Composite materials are becoming ever more popular in an increasing number of applications. This because of their many advantages, amongst others the possibility to create a new material of given characteristics in a quite simple way by changing either the type of matrix, or reinforcement, and/or rearranging the reinforcement in a different way. Of course, once a new material is created, it is necessary to characterize it to verify its suitability for a specific exploitation. In this context, infrared thermography (IRT) represents a viable means since it is noncontact, nonintrusive, and can be used either for nondestructive evaluation to detect manufacturing defects, or fatigue-induced degradation, or else for monitoring the inline response to applied loads. In this work, IRT is used to investigate different types of composite materials, which involve carbon fibers embedded in a thermoset matrix and either glass or jute fibers embedded in a thermoplastic matrix, which may be neat, or modified by the addition of a percentage of a specific compatibilizing agent. IRT is used with a twofold function. First, for nondestructive evaluation, with the lock-in technique, before and after loading to either assure absence of manufacturing defects, or discover the damage caused by the loads. Second, for visualization of thermal effects, which develop when the material is subjected to impact. The obtained results show that it is possible to follow inline what happens to the material (bending, delamination, and eventual failure) under impact and get information, which may be valuable to deepen the complex impact damaging mechanisms of composites.