High-frequency guided ultrasonic waves for hidden defect detection in multi-layered aircraft structures

Detection and localization of corrosion using the combination information of multiple Lamb wave modes

Themulti-modeanddispersionnature of Lamb waves means that a variety of modes with individual mode structures and distinct dispersion behaviors would propagate in the structures simultaneously. The existence of a corrosion would result in thickness reduction, which means the frequency-thickness product under a specific excitation would also decrease. Due to dispersion diversity, the interaction of each individual Lamb mode at the corrosion may be distinct, i.e., the velocity varies in different extent and even in opposite trends. In this paper, the combination of multiple modes, rather than a single sensitive mode, is used for structure diagnosis. Specifically, two Lamb modes both sensitive to corrosion but with opposite variation trends are taken and the corrosion index is defined on the ratio of their time-of-flight, so as to enhance the sensitivity to corrosion and eliminate the influence of difference path lengths in the sensor network. On this basis, a probabilistic reconstruction algorithm is introduced for corrosion detection and localization. Since the two modes are extracted from the same wideband Lamb wave response, the proposed method is baseline-free. The influence of mode conversion on the effectiveness of the proposed method is discussed. Ultimately, the performance of the proposed method is demonstrated by an experimental example. The results show that the defect could be correctly identified and accurately localized.

A Variable Kinematic Multifield Model for the Lamb Wave Propagation Analysis in Smart Panels

The present paper assessed the use of variable kinematic two-dimensional elements in the dynamic analysis of Lamb waves propagation in an isotropic plate with piezo-patches. The multi-field finite element model used in this work was based on the Carrera Unified Formulation which offers a versatile application enabling the model to apply the desired order theory. The used variable kinematic model allowed for the kinematic model to vary in space, thereby providing the possibility to implement a classical plate model in collaboration with a refined kinematic model in selected areas where higher order kinematics are needed. The propagation of the symmetric (S0) and the antisymmetric (A0) fundamental lamb waves in an isotropic strip was considered in both mechanical and piezo-elastic plate models. The convergence of the models was discussed for different kinematics approaches, under different mesh refinement, and under different time steps. The results were compared to the exact solution proposed in the literature in order to assess and further determine the effects of the different parameters used when dynamically modeling a Lamb wave propagating in such material. It was shown that the higher order kinematic models delivered a higher accuracy of the propagating wave evaluated using the corresponding Time Of Flight (TOF). Upon using the appropriate mesh refinement of 2000 elements and sufficient time steps of 4000 steps, the error between the TOF obtained analytically and numerically using a high order kinematics was found to be less than 1% for both types of fundamental Lamb waves S0 and A0. Node-dependent kinematics models were also exploited in wave propagation to decrease the computational cost and to study their effect on the accuracy of the obtained results. The obtained results show, in both the mechanical and the piezo-electric models, that a reduction in the computational cost of up to 50% can be easily attained using such models while maintaining an error inferior to 1%.

Use of Surface Acoustic Waves for Crack Detection on Railway Track Components—Laboratory Tests

The present work investigates the technical feasibility of a condition monitoring setup aiming at the detection of gauge corner cracks (aka head checks) in pearlitic railway rails, using a wayside (i.e., stationary) setup with surface acoustic waves (SAW) as its detection principle. The experimental SAW setup consists of a pitch-catch setup using piezo transducers equipped with comb adaptors to excite and measure narrowband Rayleigh waves with a center frequency of 1 MHz. SAW experiments were performed on a rail subjected to cyclic loading in a 1:1 wheel–rail test rig yielding the specific rolling contact fatigue, i.e., head checks. Elastodynamic finite integration technique (EFIT) simulations were performed to analyze the surface and bulk wave propagation in the rail and to predict the signals at specific receiver positions. SAW transmission and reflection scenarios at cracks were analyzed numerically via modelled variations of gauge corner crack configurations according to number of cracks (0–3) and depth (0, 0.5 mm and 1 mm). The numerical and the experimental results each show a clear correlation between the appearance and intensity of head check damage and the wave attenuation in transmission mode.

Delamination Detection in Bimetallic Composite Using Laser Ultrasonic Bulk Waves

In this study, a method based on laser ultrasonic bulk waves is used to detect delamination in a bimetallic composite. For this purpose, several artificial delamination defects were created in a copper-aluminum sample using wire-electrode cutting. The research includes numerical simulation and experimental analysis. The propagation process of laser ultrasonic in Cu/Al bimetallic compo-site, the interaction between bulk waves and composite interface, and the effect of delamination defects on the ultrasound field were studied by numerical simulation. Suitable parameters and features were determined by numerical simulation, which provided a basis for the parameter se-lection of experimental research. The reflected shear waves from the composite interface can act as a sensitive feature to detect the delamination in Cu/Al bimetallic composites. The distance between the detection point and the excitation point was set to 2 mm to take into account the detection resolution and efficiency. The experimental results were in good agreement with the simulation results, and the C-scan image can intuitively show the location and size of delamination defects. The detection method based on laser ultrasonic bulk waves can effectively detect the delamination in Cu/Al bimetallic composite, which is suitable for the on-line detection of the rolling composite process.

Analysis of Wave Patterns Under the Region of Macro-Fiber Composite Transducer to Improve the Analytical Modelling for Directivity Calculation in Isotropic Medium

Analytical modelling is an efficient approach to estimate the directivity of a transducer generating guided waves in the research field of ultrasonic non-destructive testing of the large and complex structures due to its short processing time as compared to the numerical modelling and experimental techniques. The wave patterns or the amplitude variations along the region of ultrasonic transducer itself depend on its behavior, excitation frequency, and the type of propagating wave mode. Depending on the wave-pattern of a propagating wave mode, the appropriate value of the amplitude correction factor must be multiplied to the amplitudes of the excitation signal for the accurate evaluation of directivity pattern of the ultrasonic transducers generating guided waves in analytical modelling. The objective of this work is to analyse the wave patterns under the region of macro-fiber composite (MFC) transducer to improve the accuracy of a previously developed analytical model for the prediction of directivity patterns. Firstly, the amplitude correction factor based on the wave patterns under the region of P1-type MFC (MFC-2814) transducer at two different frequencies (80 kHz, 3 periods and 220 kHz, 3 period) glued on 2 mm Al alloy plate has been estimated analytically in the case of an asymmetric (A0) guided Lamb wave. The validation of analytically estimated amplitude correction factor is performed by a proposed experimental method that allows analyzing the behaviour of MFC transducer under its region by gluing MFC on bottom surface and scanning the receiver on the top surface of the sample. Later on, the estimated amplitude correction factor is included in the previously developed 2D analytical model for the improvement in the directivity patterns of the A0 mode. The modified analytical model shows a significant improvement in the directivity pattern of the A0 wave mode in comparison to the results obtained by the previous model without considering the proper wave patterns. The results reveal that errors between the directivity estimated by the present modified 2D analytical model and experimental investigation are reduced by more than 58% in comparison to the previously developed analytical model.

Defect reconstruction by non-destructive testing with laser induced ultrasonic detection

This work envisages a detailed study of two-dimensional defect localization and reconstruction, using laser generated ultrasound and its application as a remotely controlled non-destructive testing method. As an alternative to full ultrasonic or full optical approaches, we propose a hybrid configuration where ultrasound is generated by impact of laser pulses, while the detection is done with conventional transducers. We implement this approach for defect reconstruction in metallic elements and show that it combines advantages of both photonic and ultrasonic devices, reducing the drawbacks of both methods. We combine our experimental results with a high-resolution signal processing procedure based on the synthetic aperture focusing technique for the benefit of the final two-dimensional visualization of the defects.

Damage Detection Using d15 Piezoelectric Sensors in a Laminate Beam Undergoing Three-Point Bending

A major inhibition to the widespread use of laminate structures is the inability of nondestructive testing techniques to effectively evaluate the bondline integrity. This work proposes and analyzes a bondline-integrity health monitoring approach utilizing shear-mode (d15) piezoelectric transducers. The d15 transducers were embedded in the bondlines of symmetric laminate structures to monitor and evaluate the bondline integrity using ultrasonic inspection. The d15 piezoelectric transducers made of lead zirconate titanate (PZT) enabled ultrasonic inspection of bonds by actuating and sensing antisymmetric waves in laminate structures. Design considerations, fabrication process, and experimental methods for testing a laminate specimen are presented. Designs included bondline-embedded d15 PZT piezoelectric transducers with surface-mounted transverse (d31) piezoelectric transducers for signal comparison. Defects in the bondline were created by a quasi-static three-point bending test, with results showing the ability of d15 piezoelectric transducers to detect bondline damage. Two damage indices based on Pearson correlation coefficient and normalized signal energy were implemented to evaluate the presence of damage and its severity. The experimental results demonstrate the ability of bondline-embedded d15 piezoelectric transducers to be used as actuators and sensors for ultrasonic health monitoring of bondline integrity. A comparison between surface-mounted d31 PZT and bondline-embedded d15 PZT sensors was also conducted. It was seen that signals sensed by bondline-embedded d15 PZTs showed higher distortion due to bondline defects compared with the sensed signals from the surface-mounted d31 PZT.

Detection of disbonds in multi-layer bonded structures using the laser ultrasonic pulse-echo mode

The laser ultrasonic technique with a pulse-echo mode has been investigated to detect disbonds in a multi-layer bonded structure and a quantitative method has been proposed to evaluate the defect sizes. The simulations were carried out to analyze influences of spot sizes on the characteristics of laser ultrasonic reflected waves, the interaction of laser ultrasonic reflected waves with disbonds, and quantitative characterization on disbonds. A noncontact laser ultrasonic inspection system has been established to perform a series of experiments to verify the theoretical results. Laser ultrasonic C-scans based on reflected shear waves can clearly redraw appearances of disbonds in the adhesive bond. The proposed quantitative method can evaluate the sizes of disbonds within a reasonable error range. Moreover, the experimental data are in good agreement with the simulation results. Therefore, a combination of the laser ultrasonic pulse-echo mode and the proposed quantitative strategy is practical for accurate detection of disbonds in multi-layer bonded structures.

Defect Estimation in Non-Destructive Testing of Composites by Ultrasonic Guided Waves and Image Processing

The estimation of the size and location of defects in multi-layered composite structures by ultrasonic non-destructive testing using guided waves has attracted the attention of researchers for the last few decades. Although extensive signal processing techniques are available, there are only a few studies available based on image processing of the ultrasonic B-scan image to extract the size and location of defects via the process of ultrasonic non-destructive testing. This work presents an image processing technique for ultrasonic B-scan images to improve the estimation of the location and size of disbond-type defects in glass fiber-reinforced plastic materials with 25-mm and 51-mm diameters. The sample is a segment of a wind turbine blade with a variable thickness ranging from 3 to 24 mm. The experiment is performed by using a low-frequency ultrasonic system and a pair of contact-type piezoceramic transducers kept apart by a 50-mm distance and embedded on a moving mechanical panel. The B-scan image acquired by the ultrasonic pitch-catch technique is denoised by utilizing features of two-dimensional discrete wavelet transform. Thereafter, the normalized pixel densities are compared along the scanned distance on the region of interest of the image, and a −3 dB threshold is applied to the locations and sizes the defects in the spatial domain.

Air-Coupled Excitation of a Slow A₀ Mode Wave in Thin Plastic Films by an Ultrasonic PMN-32%PT Array

Ultrasonic non-destructive testing techniques (NDT) based on the application of guided waves are already used for inspection of plate-type structures made of various materials, including composite materials. Air-coupled ultrasonic techniques are used to test such structures by means of guided waves. The objective of this research was development and investigation of air-coupled excitation of a slow A₀ Lamb wave mode in thin plastic films by a PMN-32%PT ultrasonic array. It is known that when the velocity of the A₀ mode in the film is less than the ultrasound velocity in air no leaky wave is observed in a surrounding air. It opens new possibilities for NDT of composite structures. The influence of the airborne wave may be eliminated by 3D filtering in a wavenumbers-frequency domain. A special filter and corresponding signals processing technique were developed in order to obtain directivity patterns and velocity maps of the waves propagating in all directions. The measured ultrasound velocity values prove that, with the proposed method, it is possible to excite a slow A₀ Lamb wave mode and to separate it from other parasitic waves propagating in air. Measurements of the parameters of the slow A₀ mode, such as the propagation velocity in the plastic film, may be applied for the material characterization.

Identification and Characterization of Defects in Glass Fiber Reinforced Plastic by Refining the Guided Lamb Waves

In this paper, the disbond-type defect presented on glass fiber reinforced plastic material is analyzed by refining the guided Lamb wave signals. A segment of wind turbine blade is considered as a test sample. The low-frequency ultrasonic measurement system is used for the non-destructive testing of the test sample using guided waves. The P-1 type macro-fiber composite transducer as a transmitter and contact-type piezoceramic transducer as a receiver are used for the testing of a sample. The disbond type defect having a diameter of 81 mm is detected from the experimental results. To improve the accuracy in locating and sizing the defects and estimation of the time of flight and phase velocity of ultrasonic guided waves in defective region, signal processing algorithm is developed by utilizing the promising properties of various ultrasonic signal processing techniques such as wavelet transform, amplitude detection, two-dimensional Fast-Fourier transform, Hilbert transform and variational mode decomposition. The discrete wavelet transform is used to denoise the guided wave signals and then, the size and location of defects are estimated by amplitude detection. The reflected wave signals from the opposite edge of the sample are removed by applying the two-dimensional Fast-Fourier transform to the experimental B-scan signal. Afterwards, variational mode decomposition and Hilbert transform are used for the phase velocity and time-delay estimation by comparing the instantaneous amplitudes of the defective and defect-free signal. The validation and the demonstration of reproducibility of the algorithm is performed by extracting the features of a 51 mm defect from another experimental B-scan.

Peri-ultrasound modeling for surface wave propagation

The interaction between surface wave and a surface breaking crack is studied using a novel fast modeling tool called peri-ultrasound that can model both linear and nonlinear ultrasonic response. This modeling approach is based on peridynamic theory. In this study, the surface wave is modeled by applying a triangular pulse excitation function on the surface of a large structure. The particle movements are simulated on both sides of the surface crack to investigate transmitted and reflected fields. This investigation shows that: (1) the computed amplitude spectra of the Rayleigh wave agrees with the experimental observation; and (2) the structure containing a surface breaking crack shows noticeable increase in its nonlinear behavior. The computed results have been also verified against the analytical solution for a half-plane problem made of homogenous, isotropic, linear elastic material (Lamb's Problem).

Efficient simulation of elastic guided waves interacting with notches, adhesive joints, delaminations and inclined edges in plate structures

This paper presents an approach to model transmission and reflection phenomena of elastic guided waves in plates. The formulation is applied to plate structures containing notches, inclined edges, delaminations or (adhesive) joints. For these cases, only the thickness direction of the structure needs to be discretized at several locations, while the direction of propagation is described analytically. Consequently, the number of degrees of freedom is very small. Semi-infinite domains can be modeled, in which case the radiation condition is fulfilled exactly. Traction boundary conditions are introduced on the plate surface without requiring a mesh along the surface. Results are validated against conventional finite element implementations, showing the accuracy of the proposed approach and a reduction of the computational costs by typically 2-3 orders of magnitude.

Reflection and transmission coefficients of the SH0 mode in the adhesive structures with imperfect interface

Compared with body waves, ultrasonic guided waves can provide more local characteristic information about the interface in the defect detection of adhesive structures. In the paper, the expressions of the reflection and transmission coefficients of the lowest SH mode (SH0) in multilayered plate-like adhesive structure were deduced on the basis of wave propagation controlling equations and tangential stiffness coefficient KT was contained in the expressions. Then, the expressions were compared with the previous results to verify their applicability and correctness. Then, aluminum/epoxy resin/aluminum adhesive structures were used to explore the effects of the changes in incident angle, frequency-thickness product and tangential stiffness coefficient on SH wave propagation characteristics in adhesive structures with different interface quality (perfect, weak bonding, and slip/debonding interfaces). The results showed that the propagation mode of SH wave in adhesive structures was mainly determined by the incident angle, frequency, adhesive layer thickness and tangential stiffness coefficient. With the increase in the frequency-thickness product, multi-order resonance is generated in the reflection and transmission coefficient curves of SH wave under the perfect and weak bonding interfaces. If proper values of the incident angle of acoustic waves and frequency-thickness product are selected, the perfect, weak bonding, and slip/debonding interfaces can be differentiated from each other, but the slip and debonding interfaces cannot be distinguished from each other. The study provides theoretical contribution to the detection of multilayered plate-like adhesive structure by SH wave.

Characterisation of hidden defects using the near-field ultrasonic enhancement of Lamb waves

Defects that propagate from the inside of a structure can be difficult to detect by traditional non-destructive inspection methods. A non-contact inspection method is presented here that uses the near-field interactions of ultrasonic Lamb waves to detect defects propagating into a 1.5 mm thick aluminium sheet from the opposite side to that which is inspected. Near-field interactions of the S0 Lamb waves with the defects are shown to give rise to a characteristic increase in the wave magnitude, which is used to position and characterise these hidden defects. It is shown that such defects are difficult to detect from a study of their influence on ultrasonic transmission alone. Single defects of different depths, and systems of multiple defects with varying separations and relative depths, are successfully detected in both experimental trials and FEM simulations. Reliable single defect detection is achieved for defects with a minimum depth of 30% of the plate thickness, and resolution of multiple defects is achieved for defect separations of 5mm.