High signal-to-noise-ratio ultrasonic imaging of crack defects in particles filled composite explosives

Abstract

<sec>Polymer bonded explosive (PBX) is a kind of composite material with highly filled molding explosive particles (normally more than 95%) and a small quantity of binders (less than 5%). The effective detection of internal cracks in PBX is of great significance in evaluating structural integrity and safety reliability.</sec><sec>Ultrasonic phased array detection and imaging methods show great advantages and potential in detecting crack defects. But acoustic test results indicate that the PBX has unique characteristics with low longitudinal wave velocity (～3000 m·s<sup>–1</sup>) and strong attenuation (attenuation coefficient ～400 dB·m<sup>–1</sup> for 2.5 MHz ultrasound). When the defect is imaged by traditional ultrasonic total focusing method (TFM), the structural noises at the boundaries between particles lead to low signal-to-noise ratio (SNR) in the FMC signals and strong background noise in reconstructed image, which will disturb the detection of cracks.</sec><sec>To realize the high SNR imaging of crack defects in PBX, an ultrasonic imaging algorithm based on baseband nonlinear synthetic focusing (BB-NSF) is proposed. By utilizing the spatial coherence of the received signals in full matrix capture (FMC) data, the pixel intensity at defect position can be enhanced while the background noise can be drastically weakened. The delay rule of the algorithm is modified according to the characteristics of PBX surface configuration. In this way, the high SNR imaging of crack defects with different orientations of PBX surface configuration is realized, and the quality of the reconstructed images is compared and evaluated quantitatively. Meanwhile, the base band transformation in calculation process optimization could significantly reduce calculation burden and increase imaging efficiency.</sec><sec>Experimental results show that the proposed algorithm can effectively suppress background noise and significantly improve the ability to detect the PBX cracks. The effective suppression to background noise makes the defect more highlighting and distinguished easily. For the BB-NSF algorithm, spatial coherence coefficient <i>p</i> is a crucial parameter used for dynamically regulating the SNR of reconstructed image. When <i>p</i> value is more than 2.0, the SNR of the ultrasonic reconstructed image of PBX crack defect is improved by more than 10 dB compared with that of the traditional linear synthetic focusing imaging. With the increase of <i>p</i> value, the SNR is further improved, while the calculation efficiency for a single image is almost kept stable. Moreover, the increase of SNR to some extent will improve the far-field detect capability.</sec><sec>Besides, with the BB-NSF algorithm, flexible transducer inhibits different imaging characteristics of for cracks with different orientations and depths in curved PBX specimens. For defects with large orientation angle and buried depth, the tip, root and shape of cracks can be completely present. For defects with small orientation angle and buried depth, part of shape and contour features will be lost.</sec><sec>In conclusion, the BB-NSF algorithm shows the advantage of high SNR and calculation efficiency in imaging PBX cracks, and exhibits great application prospect in imaging internal defects of other strongly attenuated composites.</sec>