The effects of stress and crack morphology on time-of-flight diffraction signals

Abstract

A model based on the theory of infinite contacting surfaces is used to analyse the transmission and reflection of ultrasound at tight fatigue cracks under compressive stress. The model developed is valid for both compression and shear (SV) waves incident at arbitrary angles on a fatigue crack and includes mode conversion effects. In discussing diffraction of ultrasound by the tips of finite length fatigue cracks, we associate the amplitude of the diffracted signal with the strength of the signal reflected from cracks of infinite extent. Thus we allow all the energy transmitted by the tight crack to play no part in the diffraction process. Comparison is made with experiments carried out at Harwell and we conclude that, for these particular experiments, the cracks are fully open when subjected to about 88 MPa of tension, and that the experimental results are consistent with a root mean square deviation from flatness of the crack faces of about 1·5 μm. This is in broad agreement with the actual crack profile when a sampling length of about 30 μm is used. Using these values the theory and experiment show excellent agreement to within 2 dB over the whole applied stress range. The results show, for example, a diffraction signal decreased by a maximum of about 13 dB when the applied compressive load corresponds to 70% of the maximum load used during crack growth. Similar conclusions are also drawn for conventional pulse-echo inspection, whereas Tandem suffers a greater reduction in signal strength due to the usually lower frequency.