Measurement of coating–substrate interface stiffness using a constructed ultrasonic echo phase derivative spectrum

Abstract

Measurement of coating–substrate interface stiffness can indirectly characterize interface bonding quality. This paper proposes a noval quantitative inversion coating–substrate interface stiffness method based on the multi-resonance frequencies of a constructed ultrasonic echo phase derivative spectrum (UEPDS). The theoretical relationship between UEPDS resonance frequencies and interface stiffness is derived. The detection frequency and high-sensitivity interface stiffness range are optimized based on the sensitivity analyzed. Numerical simulation and experiment are implemented on a 0.48 mm aluminum layer/carbon steel substrate specimen to prove the validity of the proposed ultrasonic method. The simulation results show that the maximal relative error between the inversion and the preset interface stiffnesses is reduced from 23% to 8% compared with the traditional ultrasonic reflection coefficient amplitude spectrum-based (URCAS-based) method. The experiment results indicate that the UEPDS-based inversion interface stiffnesses have the same trend as the nominal contact pressures between the coating–substrate interface.