Laser ultrasonic diagnostics of residual stress

Off-epicentral measurement of laser-ultrasonic shear-wave velocity and its application to elastic-moduli evaluation

This study investigates the off-epicentral measurement system and methodology of laser-ultrasonic shear waves in the ablative regime, subsequently focusing on its application to the elastic-moduli evaluation. The proposed scheme facilitates the measurement of the shear-wave velocity by using the crosscorrelation of successive shear-wave pulse echoes, ensuring high reliability and reproducibility of the calculation results. Since the geometric diffraction induced by the finite dimensions of laser-ultrasonic source and receiver can increase the measurement error, far-field diffraction correction for the off-epicenter detection has been derived theoretically. Results have shown that the far-field diffraction correction error is of the same order as random error mainly caused by the finite observation time, signal-to-noise ratio and frequency bandwidth, and therefore cannot be neglected. The feasibility of this approach is then demonstrated by inspecting annealed commercial purity titanium plates. Good agreement of experimentally measured and theoretical values of shear-wave velocity confirms the validity of the proposed approach. The ultrasonic measurement-determined shear modulus shows a maximum deviation of ＋3.6% from the standard value of an isotropic material.

A Review of Non-Destructive Testing (NDT) Techniques for Defect Detection: Application to Fusion Welding and Future Wire Arc Additive Manufacturing Processes

In Wire and Arc Additive Manufacturing (WAAM) and fusion welding, various defects such as porosity, cracks, deformation and lack of fusion can occur during the fabrication process. These have a strong impact on the mechanical properties and can also lead to failure of the manufactured parts during service. These defects can be recognized using non-destructive testing (NDT) methods so that the examined workpiece is not harmed. This paper provides a comprehensive overview of various NDT techniques for WAAM and fusion welding, including laser-ultrasonic, acoustic emission with an airborne optical microphone, optical emission spectroscopy, laser-induced breakdown spectroscopy, laser opto-ultrasonic dual detection, thermography and also in-process defect detection via weld current monitoring with an oscilloscope. In addition, the novel research conducted, its operating principle and the equipment required to perform these techniques are presented. The minimum defect size that can be identified via NDT methods has been obtained from previous academic research or from tests carried out by companies. The use of these techniques in WAAM and fusion welding applications makes it possible to detect defects and to take a step towards the production of high-quality final components.

Quality inspection of micro solder joints in laser spot welding by laser ultrasonic method

The quality inspection of micro solder joints in laser spot welding (LSW) is a problem of great concern in industrial application. In this paper, a laser ultrasonic technology (LUT) was proposed to inspect the quality of micro solder joints in LSW. Firstly, based on the thermoelastic model of acoustic wave propagation in solid, a theoretical model was built and used to analyze the propagation properties of the Lamb wave in the whole field by finite element method (FEM), the transmitting properties of the excited Lamb wave via solder joint were affected by the effective contacted area of solder joint. Secondly, LUT was used to inspect the 1.2 mm/0.4 mm welding spot of standard/false 304 stainless steel welded components. By comparing the propagating properties of excited ultrasonic wave in different samples with different weld quality, the standard and false welding can be visually distinguished. Finally, a industrial CT was used to check the quality of the samples used in our experiment. Inclusions and pores have been found in the false solder joints, which will reduce the effective contacted area of solder joint, and then affected the propagation of ultrasonic wave. By combining the CT results and the experimental analysis, the experimental results detected by LUT are in good agreement with the simulation results. So, the LUT is a potential method in field of the quality inspection of micro solder joints in LSW.

Research on the influence of heat treatment on residual stress of TC4 alloy produced by laser additive manufacturing based on laser ultrasonic technique

During the laser additive manufacturing (LAM) process large temperature gradients can lead to high level of residual stress. The residual stress can have irreversible effects such as warping and cracking of parts during and post manufacturing. Heat treatment is an effective method to control and eliminate residual stress. In this paper, the TC4 parts are prepared by laser additive manufacturing, and the influence of heat treatment process on residual stress is researched. Laser ultrasonic technology, as an advanced nondestructive testing method, is applied to measure the residual stress under different heat treatment processes for the first time. The surface wave generated by laser is used to evaluate the residual stress. The results show that laser ultrasonic method can complete the in-situ evaluation of residual stress in additive manufacturing components. The residual stress in TC4 deposited specimen is large, the longitudinal stress is obviously greater than the transverse stress, and the maximum residual stress is about half of the yield strength. The residual stress increases gradually from the upper surface to the bottom layer near the substrate before heat treatment. After heat treatment, the residual stress is reduced to low stress level and a small compressive stress appears. The cooling rate and solution temperature are the main factors affecting the residual stress, and the residual stress increases with the increase of cooling rate and solution temperature. The effect of aging temperature and aging time on residual stress is not obvious. The study serves as useful guidelines for engineers to assessment and regulation of residual stress reasonably in LAM.

Simultaneous Compositional and Grain Size Measurements Using Laser Opto-Ultrasonic Dual Detection for Additive Manufacturing

Metal-based additive manufacturing (AM) is a disruptive technique with great potential across multiple industries; however, its manufacturing quality is unstable, leading to an urgent requirement for component properties detection. The distribution of grain size has an important effect on many mechanical properties in AM, while the distribution of added elements, such as titanium (Ti), has a measurable effect on the grain size of an aluminum (Al) alloy. Therefore, the detection of the distributions of grain size and elements is of great significance for AM. In this study, we investigated the distribution of grain size and elements simultaneously for wire + arc additive manufacturing (WAAM) with an Al alloy using laser opto-ultrasonic dual (LOUD) detection. The average grain size obtained from the acoustic attenuation of ultrasonic signals was consistent with the results of electron backscatter diffraction (EBSD), with a coefficient of determination (R²) of 0.981 for linear fitting. The Ti element distribution obtained from optical spectra showed that the enrichment of Ti corresponded to the grain refinement area in the detected area. The X-ray diffraction (XRD) spectra showed that the spectral peaks were moved from Al to AlTi and Al₂Ti forms in the Ti-rich areas, which confirmed the LOUD results. The results indicated that LOUD detection holds promise for becoming an effective method of analyzing the mechanical and chemical properties of components simultaneously, which could help explain the complex physical and chemical changes in AM and ultimately improve the manufacturing quality.

Mechanical Strength Evaluation of Elastic Materials by Multiphysical Nondestructive Methods: A Review

The main purpose of industrial nondestructive testing (NDT) is to diagnose the stability, reliability and failure probability of materials, components and structures. Industrial component mechanical strength is one of the most important properties NDT is used to characterize. Subtle but perceptible changes in stress-strain behavior can be reliable indicators of defect formation. A detailed review on the state-of-the-art NDT methods using optical-radiation, photoacoustic, and photothermal techniques for mechanical strength evaluation and defect pre-diagnosis is presented in this article. Mechanical strength is analyzed in terms of the deformation/strain field, the stress-strain relation, and the residual stress in an elastic material subjected to tensile or compressive loading, or impact. By introducing typical NDT experiments, the history and features of each methodology are revisited and typical applications are discussed. This review also aims to be used as a reference toward further research and development of NDT technologies characterizing mechanical strength of materials and components.

Influence of Uniaxial Stress on the Shear-Wave Spectrum Propagating in Steel Members

Structural health monitoring technologies have provided extensive methods to sense the stress of steel structures. However, monitored stress is a relative value rather than an absolute value in the structure’s current state. Among all the stress measurement methods, ultrasonic methods have shown great promise. The shear-wave amplitude spectrum and phase spectrum contain stress information along the propagation path. In this study, the influence of uniaxial stress on the amplitude and phase spectra of a shear wave propagating in steel members was investigated. Furthermore, the shear-wave amplitude spectrum and phase spectrum were compared in terms of characteristic frequency (CF) collection, parametric calibration, and absolute stress measurement principles. Specifically, the theoretical expressions of the shear-wave amplitude and phase spectra were derived. Three steel members were used to investigate the effect of the uniaxial stress on the shear-wave amplitude and phase spectra. CFs were extracted and used to calibrate the parameters in the stress measurement formula. A linear relationship was established between the inverse of the CF and its corresponding stress value. The test results show that both the shear-wave amplitude and phase spectra can be used to evaluate uniaxial stress in structural steel members.

A Basic Complete Numerical Toolbox for Picosecond Ultrasonics

A complete numerical complete toolbox is proposed concerning the simulation of photo-induced propagative mechanical wave, and concerning the optical reflectometric measured response of the material, which is initially exposed to a first pump laser beam that photo-induces the acoustic wavefronts. The deformation field and its propagation into a bulk material are simulated. Based on this field expression, the complex transient reflectivity is given for a medium considered as homogeneous. The real part of this quantity permits afterwards to propose a numerical simulation of the transient reflectivity, which corresponds to the optical signal measured during experimental works. The frequency acoustic spectrum is simulated and successfully compared to the measured frequency spectrum. For the first time, numerical complete developments are explicitly proposed and fully-developed under the SciLab ® environment, related to the simulation of laser-induced picosecond acoustic wavefront photogenerated through an opto-acoustic transduction process (ultrasonics and pretersonics).

Residual Stress in Laser Welding of TC4 Titanium Alloy Based on Ultrasonic laser Technology

Laser welding is widely used in titanium alloy welding due to its high energy density, small heat affected zone, and rapid processing ability. However, problems with laser welding, such as deformation and cracking caused by residual stress, need to be resolved. In this paper, the residual stress in laser welding of TC4 titanium alloy was studied using an ultrasonic laser. The residual stress in titanium alloy plates is considered a plane stress state. A pre-stress loading method is proposed and acoustoelastic coefficients are obtained. Based on the known acoustoelastic coefficients, the transverse and longitudinal residual stresses in laser welding are measured using an ultrasonic laser. The results show that longitudinal residual stress is greater than the transverse stress. The distribution regularity of the residual stress is similar to normal welding, but the tensile stress zone is much narrower. Then, the influence of heat input and welding speed on residual stress is discussed. With increasing heat input, the welding zone widens, and the peak value of the residual stress increases. A higher welding speed should be chosen when the welding power is constant. This research has important significance for the measurement and control of residual stress in the laser welding process.

A new method for plastic strain measurement with Rayleigh wave polarization

In this work, a new non-contact and coupling-free ultrasound method with measuring Rayleigh wave polarization (RWP) by electromagnetic acoustic transducers (EMATs) is applied for plastic strain measurement, which can provide a very promising alternative and reference-free ultrasonic testing technique with high spatial resolution. Two specially designed EMAT receivers are developed to measure the polarization of Rayleigh wave generated by an enhanced meander-line-coil EMAT. The change in RWP due to the plastic strain has been successfully measured. And the measurement results indicate that the plastic strain at the specimen surface can be evaluated with good accuracy by measuring the relative change in RWP with the proposed EMAT-based method.

Laser-induced ultrasonic imaging for measurements of solid surfaces in optically opaque liquids [Invited]

The paper describes a novel laser ultrasonic profilometry method which uses pulsed laser radiation for imaging of the surface profile of solid objects in optically opaque liquids by scattering of ultrasonic waves. Algorithms for the construction of laser ultrasonic images and for profile segmentation are presented. An experimental setup for profile measurements is described. It allows reconstructing of laser ultrasonic images with a frame rate of 10 Hz and performing an automated 3D scanning of samples. The results of the experimental testing of laser ultrasonic profilometry on duralumin samples are presented. The approximation error of duralumin cylinder surface profile measurements in water is 15 μm. The results are compared to those obtained by x-ray tomography.

Experiment and numerical simulation for laser ultrasonic measurement of residual stress

Laser ultrasonic is a most promising method for non-destructive evaluation of residual stress. The residual stress of thin steel plate is measured by laser ultrasonic technique. The pre-stress loading device is designed which can easily realize the condition of the specimen being laser ultrasonic tested at the same time in the known stress state. By the method of pre-stress loading, the acoustoelastic constants are obtained and the effect of different test directions on the results of surface wave velocity measurement is discussed. On the basis of known acoustoelastic constants, the longitudinal and transverse welding residual stresses are measured by the laser ultrasonic technique. The finite element method is used to simulate the process of surface wave detection of welding residual stress. The pulsed laser is equivalent to the surface load and the relationship between the physical parameters of the laser and the load is established by the correction coefficient. The welding residual stress of the specimen is realized by the ABAQUS function module of predefined field. The results of finite element analysis are in good agreement with the experimental method. The simple and effective numerical and experimental methods for laser ultrasonic measurement of residual stress are demonstrated.

Experimental study and finite element analysis based on equivalent load method for laser ultrasonic measurement of elastic constants

The laser ultrasonic generation of Rayleigh surface wave and longitudinal wave in an elastic plate is studied by experiment and finite element method. In order to eliminate the measurement error and the time delay of the experimental system, the linear fitting method of experimental data is applied. The finite element analysis software ABAQUS is used to simulate the propagation of Rayleigh surface wave and longitudinal wave caused by laser excitation on a sheet metal sample surface. The equivalent load method is proposed and applied. The pulsed laser is equivalent to the surface load in time and space domain to meet the Gaussian profile. The relationship between the physical parameters of the laser and the load is established by the correction factor. The numerical solution is in good agreement with the experimental result. The simple and effective numerical and experimental methods for laser ultrasonic measurement of the elastic constants are demonstrated.

Adaptive Light Modulation for Improved Resolution and Efficiency in All-Optical Pulse-Echo Ultrasound

In biomedical all-optical pulse-echo ultrasound systems, ultrasound is generated with the photoacoustic effect by illuminating an optically absorbing structure with a temporally modulated light source. Nanosecond range laser pulses are typically used, which can yield bandwidths exceeding 100 MHz. However, acoustical attenuation within tissue or nonuniformities in the detector or source power spectra result in energy loss at the affected frequencies and in a reduced overall system efficiency. In this work, a laser diode is used to generate linear and nonlinear chirp optical modulations that are extended to microsecond time scales, with bandwidths constrained to the system sensitivity. Compared to those obtained using a 2-ns pulsed laser, pulse-echo images of a phantom obtained using linear chirp excitation exhibit similar axial resolution (99 versus 92 μm, respectively) and signal-to-noise ratios (SNRs) (10.3 versus 9.6 dB). In addition, the axial point spread function (PSF) exhibits lower sidelobe levels in the case of chirp modulation. Using nonlinear (time-stretched) chirp excitations, where the nonlinearity is computed from measurements of the spectral sensitivity of the system, the power spectrum of the imaging system was flattened and its bandwidth broadened. Consequently, the PSF has a narrower axial extent and still lower sidelobe levels. Pulse-echo images acquired with time-stretched chirps as optical modulation have higher axial resolution (64 μm) than those obtained with linear chirps, at the expense of a lower SNR (6.8 dB). Using a linear or time-stretched chirp, the conversion efficiency from optical power to acoustical pressure improved by a factor of 70 or 61, respectively, compared to that obtained with pulsed excitation.

Remarks on residual stress measurement by hole-drilling and electronic speckle pattern interferometry

Hole drilling is the most widespread method for measuring residual stress. It is based on the principle that drilling a hole in the material causes a local stress relaxation; the initial residual stress can be calculated by measuring strain in correspondence with each drill depth. Recently optical techniques were introduced to measure strain; in this case, the accuracy of the final results depends, among other factors, on the proper choice of the area of analysis. Deformations are in fact analyzed within an annulus determined by two parameters: the internal and the external radius. In this paper, the influence of the choice of the area of analysis was analysed. A known stress field was introduced on a Ti grade 5 sample and then the stress was measured in correspondence with different values of the internal and the external radius of analysis; results were finally compared with the expected theoretical value.