Efficient testing of weld seam models with radii of curvature in the millimeter range using laser ultrasound

Laser ultrasound is a widely used tool for industrial quality assurance when a contactless and fast method is required. In this work, we used a laboratory setup based on a confocal Fabry-Perot interferometer to examine weld seam models. The focus was placed on small samples with curved surfaces (small in the sense that the radius of curvature is comparable to the largest ultrasonic wavelength) and on efficient ways to detect the presence and volume of process pores, with the goal to transfer this method to industrial applications. In addition to this experimental method for investigating welds, a numerical method that models the experimental setup was implemented in MATLAB. For this purpose, first the thermal effects of the excitation process were taken into account by solving the thermal diffusion equation with an explicit scheme. Then, the elastodynamic equations were solved using the Elastodynamic Finite Integration Technique, taking into account the stresses induced by the excitation process. The B-Scans generated with this numerical model were compared with experimental B-Scans for simple test cases and good agreement was found. In a next step, the additional structures in the B-Scans resulting from air inclusions were identified and investigated with both methods using flat test specimens at first. Besides the direct echoes, structures from skimming surface waves and multiple reflections were visible. These additional structures are unwanted in defect reconstruction methods like the Synthetic Aperture Focusing Technique (SAFT) as they would lead to artifacts. In samples much larger than the largest ultrasound wavelength, however, these unwanted structures are still negligible in amplitude or can be well separated temporally, but for small samples this is no longer the case. As a result, reconstruction methods based on direct echoes like SAFT are difficult to apply. For many industrial applications, the reconstruction is not decisive at all, but only the knowledge of the total volume of process pores (TVPP). It is shown with both experimental and numerical methods, that this TVPP can be estimated from the variation in the B-Scans from various small weld seam models.

Carbon nanofibers/liquid metal composites for high temperature laser ultrasound

As the demand for clean energy becomes greater worldwide, there will also be an increasing demand for next generation nuclear power plants that incorporate advanced sensors and monitoring equipment. A major challenge posed by nuclear power plants is that, during normal operation, the reactor compartment is subjected to high operating temperatures and radiation flux. Diagnostic sensors monitoring such structures are also subject to temperatures reaching hundreds of degrees Celsius, which puts them at risk for heat degradation. In this work, the ability of carbon nanofibers to work in conjunction with a liquid metal as a photoacoustic transmitter was demonstrated at high temperatures. Fields metal, a Bi-In-Sn eutectic, and gallium are compared as acoustic mediums. Fields metal was shown experimentally to have superior performance over gallium and other reference cases. Under stimulation from a low fluence 6 ns pulse laser at 6 mJ/cm2 with 532 nm green light, the Fields metal transducer transmitted a 200 kHz longitudinal wave with amplitude >5.5 times that generated by a gallium transducer at 300 °C. Each high temperature test was conducted from a hot to cold progression, beginning as high as 300 °C, and then cooling down to 100 °C. Each test shows increasing signal amplitude of the liquid metal transducers as temperature decreases. Carbon nanofibers show a strong improvement over previously used candle-soot nanoparticles in both their ability to produce strong acoustic signals and absorb higher laser fluences up to 12 mJ/cm2.

Suppressing artifacts in the total focusing method using the directivity of laser ultrasound

Based on a synthesized laser ultrasonic array, full matrix capture can be used to acquire data, which can then be post-processed using the total focusing method. However, this noncontact ultrasonic imaging technique has not been widely used because of the numerous artifacts in ultrasonic images and time-consuming data acquisition. To address these issues, this study proposes a post-processing algorithm, which uses the laser ultrasound directivity information to suppress the artifacts in the total focusing method's images. In particular, a weight factor is defined using the directivity information. By multiplying the image intensity of the total focusing method with this factor, the algorithm uses not only the amplitude and phase information of laser ultrasound but also its directivity information. The experimental results indicate that four types of artifacts are suppressed. Because the grating lobe artifacts can be suppressed, a larger element spacing can be used to reduce the data acquisition time.

Multi-mode laser-ultrasound imaging using Time-domain Synthetic Aperture Focusing Technique (T-SAFT)

The Synthetic Aperture Focusing Technique (SAFT) is an imaging algorithm used in laser ultrasonics (LU) to visualise the appearance of defects. However, ultrasound excited by a pulsed laser has the characteristics of wide bandwidth and multi-mode directivity patterns, leading to common problems in the SAFT process, such as low utilisation of ultrasound information and possible artefacts. To solve these problems, a Multi-mode Time-domain SAFT (MMT-SAFT) algorithm is proposed in this paper. The influence of ultrasonic directivity is discussed according to the imaging depth range, and imaging with multiple LU modes is performed to reduce artefacts. Simulations and experimental results prove the feasibility of the MMT-SAFT algorithm, which not only presents a clearer image of the upper part of defects but also improves image quality compared with time-domain SAFT using a single ultrasonic mode. The proposed technique can provide feasible directions for laser ultrasonic defect imaging.

Remote characterization of surface slots by enhanced laser-generated ultrasonic Rayleigh waves

Characterization of surface features is essential in many industrial applications, especially for features with large depths, high aspect ratios or under extreme conditions. This work presents a non-contact method to characterize surface slots with large lengths using ultrasonic Rayleigh waves generated by a pulsed laser. A delay-and-sum superposition technique is applied to enhance the signal to noise ratio of transmitted Rayleigh waves. The length of the slot can be calculated from the time-of-flight information of Rayleigh waves without any prior knowledge of its orientation, width or aspect ratio. Both numerical simulations and experiments are conducted to demonstrate the proposed method, showing excellent performance. Furthermore, mode conversion has been studied to understand its impact on the reconstruction accuracy. Given the non-contact feature of the laser ultrasonic technique, the proposed method provides a simple and feasible avenue for the rapid characterisation of normal and angled surface features with high aspect ratio in extreme environments.

Research on laser ultrasonic surface defect identification based on a support vector machine

To solve the problem of difficult quantitative identification of surface defect depth during laser ultrasonic inspection, a support vector machine-based method for quantitative identification of surface rectangular defect depth is proposed. Based on the thermal-elastic mechanism, the finite element model for laser ultrasound inspection of aluminum materials containing surface defects was developed by using the finite element software COMSOL. The interaction process between laser ultrasound and rectangular defects was simulated, and the reflected wave signals corresponding to defects of different depths under pulsed laser irradiation were obtained. Laser ultrasonic detection experiments were conducted for surface defects of different depths, and multiple sets of ultrasonic signal waveform were collected, and several feature vectors such as time-domain peak, center frequency peak, waveform factor and peak factor were extracted by using MATLAB, the quantitative defect depth identification model based on support vector machine was established. The experimental results show that the laser ultrasonic surface defect identification model based on support vector machine can achieve high accuracy prediction of defect depth, the regression coefficient of determination is kept above 0.95, and the average relative error between the true value and the predicted value is kept below 10%, and the prediction accuracy is better than that of the reflection echo method and BP neural network model.

Non-destructive laser-ultrasonic Synthetic Aperture Focusing Technique (SAFT) for 3D visualization of defects

The Laser Ultrasonic (LU) technique has been widely studied. Detected ultrasonic signals can be further processed using Synthetic Aperture Focusing Techniques (SAFTs), to detect and image internal defects. LU-based SAFT in frequency-domain (F-SAFT) is developed to visualize horizontal hole-type defects in aluminum. Bulk acoustic waves are non-destructively generated by irradiating a laser line-source, and detected using a laser Doppler vibrometer at a point away from the generation. The influence of this non-coincident generation-detection on the equivalent acoustic velocity used in the algorithm is studied via velocity mappings. Because the wide-band generation characteristic of the LU technique, frequency range selections in acoustic wave signals are implemented to increase Signal-to-Noise Ratio (SNR) and reconstruction speed. Results indicate that by using the LU F-SAFT algorithm, and incorporating optimizations such as velocity mapping and frequency range selection, small defects can be visualized in 3D with corrected locations and improved image quality.

Detection of disbonds in adhesively bonded aluminum plates using laser-generated shear acoustic waves

Adhesively bonded metals are increasingly used in many industries. Inspecting these parts remains challenging for modern non-destructive testing techniques. Laser ultrasound (LU) has shown great potential in high-resolution imaging of carbon-reinforced composites. For metals, excitation of longitudinal waves is inefficient without surface ablation. However, shear waves can be efficiently generated in the thermo-elastic regime and used to image defects in metallic structures. Here we present a compact LU system consisting of a high repetition rate diode-pumped laser to excite shear waves and noncontact detection with a highly sensitive fiber optic Sagnac interferometer to inspect adhesively bonded aluminum plates. Multiphysics finite difference simulations are performed to optimize the measurement configuration. Damage detection is performed for a structure consisting of three aluminum plates bonded with an epoxy film. Defects are simulated by a thin Teflon film. It is shown that the proposed technique can efficiently localize defects in both adhesion layers.

Toroidally focused sensor array for real-time laser-ultrasonic imaging: The first experimental study

In this paper we report on the first toroidally focused 2D real-time laser-ultrasonic imaging system and a modified filtered back projection algorithm that can be used in the region near the waist of the astigmatic laser-ultrasonic probe beam. The system is capable of visualizing an acupuncture needle 0.2 mm in diameter located at ∼4 cm depth in water. The lateral spatial resolution is better than ∼0.32 mm and axial spatial resolution is ∼30 μm. The achieved frame rate is up to 30 Hz. The depth dependency of the sensitivity region width and lateral resolution are experimentally measured and discussed. The array is intended to be used as a part of combined real-time photoacoustic and laser-ultrasonic imaging system.

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.

Study on effect of laser-induced ablation for Lamb waves in a thin plate

In this paper, the effect of ablation on the shape of elastic waves generated by laser excitation is studied numerically and experimentally. Laser-induced ultrasound has been widely used in the nondestructive testing (NDT) field because it has the advantage that the sensor does not have to be directly attached to the target structure. In the safety assessment process, low energy excitation is used, and thus the structure is not damaged. Most studies related to laser ultrasound have focused on the method of detecting cracks within the elastic range, and there have been few studies on the effect of ablation. This research consists of experiments and numerical analyses. In experiments, elastic waves were generated in an aluminum plate by projecting laser pulses with different energy intensities. The velocities in the thickness direction were measured using a Laser Doppler Velocimeter (LDV) at a point 135 mm away from the excitation point. In the numerical study, two numerical simulations were carried out using heat flux and normal stress input to mimic laser pulse excitation. A thermo-mechanical simulation by heat flux was conducted to simulate thermal expansion by the laser pulse, and the normal stress was applied to reflect the effect of radiation pressure by ablation, respectively. Waveforms were synthesized by using different magnitude ratios of the obtained numerical responses and were compared with the experiment results. It is found that the effect of radiation pressure should not be neglected if the energy intensity is large although the effect of radiation pressure decreases as the energy intensity decreases. At the energy intensity with which ablation occurs, the effects of thermal expansion and radiation pressure exist simultaneously, and the contribution to the response depends on the energy intensity.

Attenuation of laser generated ultrasound in steel at high temperatures; comparison of theory and experimental measurements

This article reexamines some recently published laser ultrasound measurements of the longitudinal attenuation coefficient obtained during annealing of two steel samples (DP600 and S550). Theoretical attenuation models based on perturbation theory are compared to these experimental measurements. It is observed that the Rayleigh attenuation formulas provide the correct qualitative agreement, but overestimate the experimental values. The more general theoretical attenuation model considered here demonstrates strong quantitative agreement, which highlights the applicability of the model during real-time metal processing.

High resolution imaging of impacted CFRP composites with a fiber-optic laser-ultrasound scanner

Damage induced in polymer composites by various impacts must be evaluated to predict a component's post-impact strength and residual lifetime, especially when impacts occur in structures related to human safety (in aircraft, for example). X-ray tomography is the conventional standard to study an internal structure with high resolution. However, it is of little use when the impacted area cannot be extracted from a structure. In addition, X-ray tomography is expensive and time-consuming. Recently, we have demonstrated that a kHz-rate laser-ultrasound (LU) scanner is very efficient both for locating large defects and evaluating the material structure. Here, we show that high-quality images of damage produced by the LU scanner in impacted carbon-fiber reinforced polymer (CFRP) composites are similar to those produced by X-ray tomograms; but they can be obtained with only single-sided access to the object under study. Potentially, the LU method can be applied to large components in-situ.

Inspection of additive-manufactured layered components

Laser powder deposition (LPD) is a rapid additive manufacturing process to produce, layer upon layer, 3D geometries or to repair high-value components. Currently there is no nondestructive technique that can guarantee absence of flaws in LPD products during manufacturing. In this paper a laser ultrasonic technique for in-line inspection of LPD components is proposed. Reference samples were manufactured from Inconel and machined flaws were created to establish the sensitivity of the technique. Numerical models of laser-generated ultrasonic waves have been created to gain a deeper understanding of physics, to optimize the set-up and to verify the experimental measurements. Results obtained on two sets of reference samples are shown. A proof-of-concept prototype has been demonstrated on some specific deposition samples with induced flaws, that were confirmed by an ultra-high sensitivity X-ray technique. Experimental outcomes prove that typical micro-defects due to the layer-by-layer deposition process, such as near-surface and surface flaws in a single layer deposit, can be detected.

NDT of fiber-reinforced composites with a new fiber-optic pump-probe laser-ultrasound system

Laser-ultrasonics is an attractive and powerful tool for the non-destructive testing and evaluation (NDT&E) of composite materials. Current systems for non-contact detection of ultrasound have relatively low sensitivity compared to contact peizotransducers. They are also expensive, difficult to adjust, and strongly influenced by environmental noise. Moreover, laser-ultrasound (LU) systems typically launch only about 50 firings per second, much slower than the kHz level pulse repetition rate of conventional systems. As demonstrated here, most of these drawbacks can be eliminated by combining a new generation of compact, inexpensive, high repetition rate nanosecond fiber lasers with new developments in fiber telecommunication optics and an optimally designed balanced probe beam detector. In particular, a modified fiber-optic balanced Sagnac interferometer is presented as part of a LU pump-probe system for NDT&E of aircraft composites. The performance of the all-optical system is demonstrated for a number of composite samples with different types and locations of inclusions.

Numerical study for a new methodology of flaws detection in train axles

Train loads and travel speeds have increased over time, requiring more efficient non-destructive inspection methods. Railway axles are critical elements; despite being designed to last more than 20 years several cases of premature failure have been recorded. Train axles are inspected regularly, but the limits associated to the traditional inspection technologies create a growing interest towards new solutions. Here a novel non-destructive inspection method of in-service axles based on non-contact data collection is presented. The propagation of surface waves, generated by a thermo-elastic laser source, is investigated using a finite element method based on dynamic explicit integration. Coupled thermo-mechanical simulations allow visualization of the ultrasonic field guiding the definition of the optimal NDT setup. The geometry of the axle and of the elements mounted on it is accurately reproduced; moreover the press fit effect caused by the wheel and the bearing rings is implemented. The current NDT techniques for railway axles require removing wheels and other components from the axle. The presented scheme uses non-contact ultrasonic generation and detection allowing non-contact in-service inspection of railway axles at trackside station. The numerical results are promising and encourage us to test the new approach experimentally.

Characterizing phantom arteries with multi-channel laser ultrasonics and photo-acoustics

Multi-channel photo-acoustic and laser ultrasonic waves are used to sense the characteristics of proxies for healthy and diseased vessels. The acquisition system is non-contacting and non-invasive with a pulsed laser source and a laser vibrometer detector. As the wave signatures of our targets are typically low in amplitude, we exploit multi-channel acquisition and processing techniques. These are commonly used in seismology to improve the signal-to-noise ratio of data. We identify vessel proxies with a diameter on the order of 1 mm, at a depth of 18 mm. Variations in scattered and photo-acoustic signatures are related to differences in vessel wall properties and content. The methods described have the potential to improve imaging and better inform interventions for atherosclerotic vessels, such as the carotid artery.