Abstract
A set of 14 diffusion-bonded test specimens with different bond qualities has been investigated by ultrasound using compressional and shear waves at normal incidence with frequencies from 2–15 MHz. The ultrasonic test results, double way transmission-to-reflection ratio and signal-to-noise ratio, have been correlated to the results of tensile tests and notched-bar toughness tests. Defects observed in metallographic and SEM images from the diffusion bonds are narrow long strips (unbonded valleys originating from the surface roughness and from coarse grains in the grinding wheel), flat areas in the bond line without enough recrystallization (areas in which the diffusion process was inhibited), and contamination with alumina powder in the bond plane. In order to gain a deeper understanding of the ultrasonic interaction with these defects and to predict optimal inspection parameters, the ultrasonic scattered amplitude has been calculated using a quasi-static model and has been compared to the experimental results. Except for the bond contaminated by alumina powder, the ultrasonic experimental data, the model calculations, and the mechanical test results are well correlated.
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