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.

Ultrasonic structural health monitoring (SHM), employing embedded piezoelectric elements to actuate and sense ultrasonic waves, has greatly advanced in recent years. This paper presents a novel approach to address the prevailing challenges in the inspection of laminated structures for delamination using shear-mode (d15) piezoelectric transducers, composed of lead zirconate titanate (PZT). To experimentally evaluate the effectiveness of the proposed approach, a beam-like laminated specimen consisting of internally embedded d15 square PZTs was fabricated with simulated delamination at the interface of an adhesive joint. The evaluation of the results showed that the location of shear-mode actuators is a critical factor to detect delamination and to predict the propagation path of delamination. Delamination initiated close to actuators is more likely to be detected owing to their remarkable sensitivity of structural stiffness surrounding their region. The antisymmetric A0 wave mode generated by these actuators exhibits high interaction with damage, suggesting internally embedded d15 PZTs are a viable approach that can potentially advance the inspection tools of ultrasonic SHM.

An important advantage of guided waves is their ability to propagate large distances and yield more information about flaws than bulk waves. Unfortunately, the multi-modal, dispersive nature of guided waves makes them difficult to use for locating flaws. In this work, we present a method and experimental data for removing the deleterious effects of multi-mode dispersion allowing for source localization at frequencies comparable to those of bulk waves. Time domain signals are obtained using a novel 64-element phased array and processed to extract wave-number, and frequency spectra. By an application of Auld's reciprocity theorem, mode amplitudes are extracted approximately using a variational method. Once mode contributions have been obtained, the dispersion for each mode can be removed via back-propagation techniques. Excepting the presence of a small artifact at high frequency-thickness products, experimental data successfully demonstrates the robustness and viability of this approach to guided wave source location.

When stress in concrete exceeds certain threshold value, microcracks are nucleated, these microcracks can propagate and coalesce forming macrocracks, resulting in the gradual decay of the mechanical properties of concrete and eventual failure of the concrete structures. For safety concerns, one needs to develop suitable nondestructive testing methods capable of detecting past overloads of concrete structures during its service life. In this work, the stress-induced damage in concrete is monitored using ultrasonic techniques, exploiting the coupling between the stress level experienced by concrete and its wave propagation parameters. Cyclic compression tests with increasing maximum load level have been performed on specimens made of concrete with coarse-grained (CG) aggregates. Experimental results have been analyzed by two different ultrasonic methods—the linear and the nonlinear ultrasonic techniques. In linear ultrasonic technique, the stress level experienced by the specimens is related to the variations in signal amplitude and velocity of ultrasonic waves. In nonlinear ultrasonic method, the sideband peak count (SPC) technique is used for revealing the stress-induced damage corresponding to each load step. In comparison to linear ultrasonic parameters, the nonlinear ultrasonic parameter SPC-I appears to be more sensitive to the variations of the internal material structures during both loading and unloading phases. Moreover, the SPC technique has shown to be capable of identifying both the initial damage due to the evolution and nucleation of microcracks at the microscopic scale, and the subsequent damages induced by high overload, resulting in an irreversible degradation of the mechanical properties.

Recently published experimental works on remotely bonded fiber Bragg grating (FBG) ultrasound (US) sensors show that they display some unique characteristics that are not observed with directly bonded FBG sensors. These studies suggest that the bonding of the optical fiber strongly influences how the ultrasound waves are coupled from the structure to the FBG sensor. In this paper, the analytical model of the structure-adhesive-optical fiber section, treated as an ultrasound coupler, is derived and analyzed to explain the observed experimental phenomena. The resulting dispersion curve shows that the ultrasound coupler possesses a cutoff frequency, above which a dispersive longitudinal mode exists. The low propagation speed of the dispersive longitudinal mode leads to multiple resonances at and above the cutoff frequency. To characterize the resonant characteristics of the ultrasound coupler, a semi-analytical model is implemented and the scattering parameters (S-parameters) are introduced for broadband time-frequency analysis. The simulation was able to reproduce the experiment observations reported by other researchers. Furthuremore, the behaviors of the remotely bonded FBG sensors can be explained based on its resonant characteristics.

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.

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.

Defect imaging algorithms play an important role in Lamb waves based researches of nondestructive testing (NDT) and structural health monitoring (SHM). In classical algorithms, the location or distribution of defects is visualized through mapping the amplitude or phase information of signals gotten by multiple inspection pairs from the time domain to every discrete spatial grid of plates. It is time-consuming in the detection of plates with large size and many transducers. Transforming the defect imaging problem into a scattering source search problem, an intelligent defect localization algorithm was proposed for NDT and SHM with the Lamb waves and sparse array. In the algorithm, the elliptic trajectory-dependent individuals of every inspection pair were extracted first, then the defect position was identified by analyzing the distribution of individuals these located at the intersection of multiply elliptic trajectories. Considering the fuzzy and diversity characteristics in the detection of defects, a fuzzy control parameter and an adaptive individual updating strategy based on the k-means algorithm were introduced to ensure the robustness of the algorithm. The effectiveness of the proposed algorithm was verified by numerical models and experiments. The influences of the fuzzy control parameter and the individual updating strategy on the performance of the algorithm were analyzed furthermore.

Adverse environmental conditions result in corrosion during the life cycle of marine structures such as pipelines, offshore oil platforms, and ships. Generalized corrosion leading to the loss of wall thickness can cause the degradation of the integrity, strength, and load bearing capacity of the structure. Nondestructive detection and monitoring of corrosion damage in difficult to access areas can be achieved using high-frequency guided waves propagating along the structure. Using standard ultrasonic wedge transducers with single-sided access to the structure, specific high-frequency guided wave modes (overlap of both fundamental Lamb wave modes) were generated that penetrate through the complete thickness of the structure. The wave propagation and interference of the guided wave modes depend on the thickness of the structure and were measured using a noncontact laser interferometer. Numerical simulations using a two-dimensional finite element model were performed to visualize and predict the guided wave propagation and energy transfer across the plate thickness. During laboratory experiments, the wall thickness was reduced uniformly by milling of one steel plate specimen. In a second step, wall thickness reduction was induced using accelerated corrosion for two mild steel plates. The corrosion damage was monitored based on the effect on the wave propagation and interference (beating effect) of the Lamb wave modes in the frequency domain. Good agreement of the measured beatlengths with theoretical predictions was achieved, and the sensitivity of the methodology was ascertained, showing that high-frequency guided waves have the potential for corrosion damage monitoring at critical and difficult to access locations.

As one of the fastest-growing technologies over the past half century, integrated circuit (IC) packaging is getting smaller and more complex. For example, typical silicon wafers in modern IC packaging have thicknesses ranging from several to tens of micrometers, and their coating layers are in the range of a few nanometers. Because the silicon wafer is the main substrate in IC packaging, it is important to accurately measure the geometry of a silicon wafer, especially its coating thickness, for process monitoring and quality control. In this study, an ultrafast ultrasonic measurement system is developed using a femtosecond laser for silicon wafer coating thickness estimation. The proposed technique provides the following unique features: (1) an ultrafast ultrasonic measurement system using a femtosecond laser is developed specifically for silicon wafer coating thickness estimation; (2) the developed system can estimate the thickness of a coating layer in the range of sub-micrometer; (3) except for the wave speed in the coating material, coating thickness can be estimated without any other prior knowledge of the coating material properties or substrate characteristics such as optical constants; and (4) the thermal effects on the ultrasonic waves propagating within a thin coating layer are explicitly considered and minimized for coating thickness estimation. Using the developed system, validation tests were successfully performed on gold-coated silicon wafers with different coating thicknesses.

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.

Ultrasonic phased array (UPA) provides a powerful tool for nondestructive testing (NDT) of carbon fiber-reinforced plastic (CFRP). By the aid of full matrix capture (FMC) technique, the optimum resolution of anisotropic CFRP inspection could be achieved by the total focusing method (TFM). The directional dependence of ultrasonic velocity is one of the biggest challenges due to the anisotropy of CFRP. The objective of this research is to establish a joint method to estimate direction-dependent velocity and damage location of CFRP. To obtain group velocity without prior knowledge of neither theoretical calculation nor experimental determination, a limited angle range of the anisotropic velocity is first obtained by backwall reflection method (BRM), which is then extended by analyzing the relation between the time delay of backwall and side drilled hole (SDH) reflection. The effectiveness of the proposed method is experimentally demonstrated with UPA imaging of SDH in composite laminates.

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.

Nonlinear ultrasonic testing is considered a more promising technique for evaluating closed cracks than conventional ultrasonic testing. However, the mechanism of the generation of nonlinear ultrasonic waves has not been sufficiently explained. We first set up a system to measure the frequency–response characteristics of ultrasonic waves and experimentally investigated the mechanism of second higher-harmonic (HH) wave generation for a fatigue crack. Sweeping the frequencies of incident waves impinging on a fatigue crack introduced to a specimen, we obtained a frequency–response characteristic curve for the crack. From the curve, resonance phenomena resulting from local defect resonance were observed. We then measured the frequency response characteristics of second HH waves using the same system and consequently confirmed that second HH waves resonated when their frequencies corresponded to the eigenfrequencies of the crack. Finally, we theoretically showed that the resonant second HH waves were generated by local defect resonance and nonlinearity.

This paper presents a modeling and simulation method for studying ultrasonic guided wave propagation in hybrid metal-composites, also known as fiber-metal laminates. The objective is to develop an efficient and versatile modeling tool to aid in the design of cost-effective nondestructive evaluation technologies. The global–local method, which combines finite element discretization and Lamb wave modal expansion is used. An extension to the traditional global–local method is made to couple the source problem with the scattering problem to deal with a surface source generating Lamb waves that interact with defects in multilayered structures. This framework is used to study the sensitivity of different excitation frequencies to ply gap defects of various sizes. The coupled model considers the transducer contact conditions and the ultrasonic system response in the Lamb wave excitation, along with the scattering phenomenon caused by the defects. This combined result is used to define the optimal excitation frequency for the strongest transmission or reflection for a given defect size that can be observed in a physical experiment. Such results can be applied to the design of a damage detection scheme in realistic aerospace structures.

Honeycomb sandwich structures (HSS) are widely used in the aerospace industry due to their high strength-to-stiffness ratio. However, these materials are susceptible to damage during manufacturing or service that can cause great loss in the load bearing capacity or even failure. Thus, periodic or continuous nondestructive evaluation (NDE) of HSS is essential for safe operation. Development of effective NDE technique is challenging due to the geometric complexity of the honeycomb core. Guided ultrasonic waves are ideal for large-scale testing because of their large propagation range and high sensitivity to defects in their path. In this paper, an improved NDE method for detecting disbonds at the top and bottom interfaces between the core and facesheets is proposed based on experimental studies. By applying excitation signals at different frequencies, the responses at the top and bottom surface of plate-like HSS component are compared and analyzed. The response in a specific frequency range is further studied by introducing disbonds at the top interface. It is shown that some components of the recorded signal in a specific frequency range are more sensitive for detecting the disbond. In addition, an improvement of the conventional damage index based on the damage feature is proposed, and a systematic procedure for detecting damage inside HSS is conducted on an elevator section of an Airbus 330. The results show that the optimized damage index greatly improves the resolution and adaptability of damage detection in the structures.

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.

Characterization of barely visible impact damage (BVID) in polymer matrix composites (PMCs) is necessary to use slow crack growth damage tolerance models and evaluate remaining life of PMC components. Azimuthally scanned angled-beam pulse-echo ultrasound is investigated as a complimentary technique to normal incidence ultrasound inspection of BVID in PMCs to characterize delamination fields. It is found that there is a correlation between signals present in the azimuthally scanned angled-beam pulse-echo ultrasound C-scans and transverse cracks seen in X-ray computed tomography inspection. These transverse cracks are not readily identifiable as transverse cracks in normal incidence C-scan inspection.

For the non-destructive inspection of carbon fiber-reinforced plastic (CFRP), lasers can be used to generate ultrasonic waves. It is important to optimize the wavelength of the laser to ensure the intense excitation of a usable propagating mode. Real CFRP components used in the construction of airplanes and automobiles are often coated with several types of resin to protect against weathering. These resin layers change the excitation of the ultrasonic waves. Thus, the optimum laser wavelength may be changed by the coating resin. In this paper, we investigated the excitation of ultrasonic waves in a resin-coated CFRP plate using different laser wavelengths. We conducted experiments to convert the laser wavelength using periodically poled LiNbO 3 (PPLN) devices. By injecting mid-infrared laser to a coated sample, we observed excited ultrasonic waves using a laser Doppler vibrometer. We found that transparent resins significantly increase the amplitude of the first-arriving longitudinal wave. Furthermore, when the laser was strongly absorbed in the surface layer, the excitation of longitudinal waves was suppressed. These results were clarified by a one-dimensional model of the thermal generation of ultrasonic waves. We concluded that a laser passing through a resin layer is a viable candidate for the effective inspection of coated CFRP by laser ultrasonic waves.