Fabrication of metal–polymer matching layers to improve some ultrasonic transducers for NDT and calibration

Abstract

This paper investigates the impact of different matching layers on the ultrasonic transducers’ performance. Matching layers are mostly used to solve the acoustic impedance matching problem between the piezoelectric element and the test specimen. To design good matching layers, we merged the metal–polymer and mass–spring systems. Their thickness was also optimized using the quarter-wavelength approach. Silver, alumina, and copper served as mass components, while parylene served as the polymer spring component. This was the first time to use such matching materials with lead zirconate titanate (PZT) transducers. The transducers’ sensitivity increased, the beam diameter broadened, the signal-to-noise ratio reduced, and the echo-height increased. According to the findings, the developed matching layers were extremely efficient in upgrading PZT transducers, making them ideal for a variety of non-destructive ultrasonic applications such as identifying defects in various materials. In addition, the new developed transducers may be useful in calibration.