Electromagnetic Acoustic Transducer Research Articles

Improved EMAT Sensor Design for Enhanced Ultrasonic Signal Detection in Steel Wire Ropes

This study is focused on optimizing electromagnetic acoustic transducer (EMAT) sensors for enhanced ultrasonic guided wave signal generation in steel cables using CAD and modern manufacturing to enable contactless ultrasonic signal transmission and reception. A lab test rig with advanced measurement and data processing was set up to test the sensors’ ability to detect cable damage, like wire breaks and abrasion, while also examining the effect of potential disruptors such as rope soiling. Machine learning algorithms were applied to improve the damage detection accuracy, leading to significant advancements in magnetostrictive measurement methods and providing a new standard for future development in this area. The use of the Vision Transformer Masked Autoencoder Architecture (ViTMAE) and generative pre-training has shown that reliable damage detection is possible despite the considerable signal fluctuations caused by rope movement.

Analytical modelling and analysis of the meander-line coil EMATs

The meander-line coil electromagnetic acoustic transducer (EMAT) is widely used in the field of ultrasonic nondestructive testing due to its convenience to generate specific mode of guided waves. Some design methods of the meander-coil EMATs are developed in the frequency-wavenumber domain while others in the time–space domain. In this paper, a unified theoretical framework is developed by proposing an analytical model from the system perspective. Signal transfers between different physical fields in EMAT excitation, wave propagation and EMAT reception are represented as linear time–space-invariant systems. Taking the Rayleigh wave EMAT detection as an example, the analytical model for the transfer functions of these systems is established. The analytical model is experimentally verified by different Rayleigh wave detection techniques: the conventional EMAT, the spatial pulse compression (SPC) EMAT, temporal-spatial pulse compression (TSPC) EMAT and detection cases employing the same receiving EMAT. From the system perspective, the received signal of EMAT is interpreted as the response of the filter system to the input signal. It is found that the meander-coil EMAT can be regarded as the frequency domain expression during the detection. And the frequency domain expression plays different roles in different techniques.

Development of a flexible phased array electromagnetic acoustic testing system with array pickups

The thermal barrier coatings (TBCs) used to protect blades of heavy-duty gas turbines is prone to debonding defects during fabrication and service. It is difficult to detect the debonding defects in the TBC system non-destructively and in situ due to the curved shape of blade and the narrow space between the blades setting in the gas turbine. In this paper, a flexible phased array electromagnetic acoustic (FPA-EMA) testing system with array pickups is developed, which is capable to drive a flexible phased array electromagnetic acoustic transducer (FPA-EMAT) to generate and receive ultrasonic wave directly in the metallic substrate of TBCs, and is potential to be applied to the inspection of debonding defects in the TBC system of gas turbine blades. A phased array excitation unit, a multi-channel signal receiving unit and a new signal post-processing algorithm are developed for the new EMA testing system to enhance the surface acoustic wave in the layered structure and to improve the low conversion efficiency of the conventional EMA testing system. In addition, a bias magnetic field coil fed with long pulse current of large amplitude is adopted to make the new EMAT thin and flexible in order to be applied in a narrow space. The interfering noise and geometric size problems brought by the multiple excitation and pickup channels are well addressed in the new system. The good performances of the developed FPA-EMA testing system were verified experimentally and show the system of good potential to be applied to NDT of practical curved structures.

A frequency steerable electromagnetic acoustic transducer

Abstract Electromagnetic acoustic transducers (EMATs) are convenient for non-destructive evaluation of plate-like structures since they can generate, without the need for contact with the medium under test, different types of ultrasonic guided waves. Guided-wave EMATs usually generate waves omnidirectionally or in a principal propagation direction. Beam steering is desirable in several applications, such as in inspections of large-area structures. This is usually achieved with several independently controlled elements forming a phased array. Alternatively, mono-element transducers with directional-dependent spectral content can steer the generated wave beam by altering the frequency of the excitation signal. A piezoelectric transducer with this characteristic, namely a frequency steerable acoustic transducer, was previously proposed. Its design was addressed in the wavenumber domain, leading to unconventional transducer shapes, but still reproducible with a piezoelectric patch, albeit unfeasible to implement as an EMAT. Here, we propose a new kind of EMAT, namely, frequency steerable EMAT (FSEMAT), whose design is addressed in the spatial domain in order to ensure its physical realization with a coil-magnet arrangement whilst still effectively presenting steering capability. The novel EMAT was designed to generate the A 0 Lamb wave mode in a frequency range from approximately 100 to 600 kHz. The FSEMAT was fabricated and experimentally evaluated in an aluminium plate at different frequencies within the designed frequency range, where each frequency corresponded to a specific propagating direction with high directivity, assessed by half-power beam widths of approximately 10 degrees. Furthermore, its theoretical directivity was computed by means of a wavenumber spectrum-based model, and showed good agreement with experimental results. The new transducer allows great flexibility effectively providing beam steering with a single EMAT.

Focused Electromagnetic Acoustic Transducers for Lamb Wave Inspection

Abstract Ultrasonic inspection of conductive samples can be performed using electromagnetic acoustic transducers (EMATs). These allow generation of guided waves, such as Lamb waves, in thin plates. Lamb waves are used for defect screening as they can travel long distances with relatively little attenuation. However, large wavelengths are used, which results in poor sensitivity to subwavelength sized defects. This work presents methods for using Lamb waves to detect smaller defects. Curved, geometrically focused EMATs were used to generate and detect Lamb waves in a 1 mm thick aluminum plate. The focal spot of these EMATs is investigated and the dependence of the focal spot dimensions and locations on the wavelength of the generation signal are presented. An array of geometrically focused detection EMATs was used to measure a 10×10×0.5mm square machined defect, simulating wall thinning. Perturbations in the pulse transmission in the region of the defect were detected, along with reflections, with each detector in the array sensitive to different defect features. B-scans and C-scans are presented utilizing these perturbations and reflections to locate, size, and image the machined defect. Analysis of data from the B-scan is shown to accurately size the defect width to within ±0.73mm. Very good agreement is shown between the C-scan images and the known location and orientation of the defect. Data fusion techniques are presented to combine data sets from different receiver EMATs and increase the defect detection capability, accuracy, and precision, with the potential for full defect sizing demonstrated.

Non-contact mechanical Q-factor measurement system based on electromagnetic acoustic transducer

The mechanical quality factor (Q-factor), which is the reciprocal of the vibration loss constant, is one of the most important parameters in vibration engineering; however, there are no methods for its precise measurement. Q-factor databases are thus commonly used. This study proposes a completely non-contact measurement system for the Q-factor that combines non-contact excitation (achieved using an electromagnetic acoustic transducer) with non-contact support (achieved using near-field ultrasonic levitation based on two Langevin transducers). The proposed method was used to measure the Q-factor for a stainless steel (SUS304) sample (thin cylindrical rod with a diameter of 1.5 mm and a length of 80 mm)and a duralumin (A2017). The 5 times average Q-factor was 2010 with standard deviation of 50 for stainless steel (SUS304), and 49,000 with standard deviation of 3900 for duralumin (A2017). The proposed method also allowed for the measurement of Young’s modulus, resulting in 217.17 ± 0.34 GPa for stainless steel (SUS304), and 71.39 ± 0.20 GPa for duralumin (A2017).

Application of coded excitation in the Rayleigh wave detection of aluminum plates with narrow-magnet EMAT

Abstract The poor generation efficiency causes the low signal-to-noise ratio (SNR) of the electromagnetic acoustic transducers (EMATs). The magnetic fields at the edges of the magnet are fully utilized in the narrow-magnet EMAT to generate Rayleigh waves of higher amplitudes than the conventional EMAT. This paper applies the coded excitation technology to narrow-magnet EMAT to further improve the SNR and the lift-off performance in aluminum plate detection. The main phase encoding methods are Barker code and Golay code. Compared with the conventional tone-burst excitation method, both coded excitation technologies can effectively improve the SNR of the Rayleigh wave. Theoretically, the received Rayleigh waves using the Golay-coded excitation method have no sidelobe, which is different from the case using the Barker code. Hence the Golay-coded excitation achieves higher SNR in the received ultrasonic waves. In addition, the application of the Golay-coded excitation can also effectively improve the lift-off performance of the narrow-magnet EMAT.

Battery state characterization based on a contactless electromagnetic ultrasound testing method

Nondestructive ultrasonic detection technology has been increasingly applied to battery diagnostics. However, currently used ultrasonic transducers must be affixed to the tested battery very tightly through coupling agents, thereby lowering the test efficiency and convenience. In this paper, a contactless electromagnetic ultrasonic testing technology is proposed for characterizing the states of lithium-ion batteries. The relationship between the ultrasonic frequency and wave velocity is analyzed via a finite element model. Meanwhile, the influence of battery boundary characteristics on ultrasonic signals is investigated. Based on the propagation characteristics of ultrasonic guided waves in the battery, contactless electromagnetic acoustic transducers (EMATs) are designed and optimized. Three features, including the time of flight, signal amplitude, and energy integration, are extracted from the received signals to indicate the variation in battery state during charging and discharging cycles. Experimental results demonstrate that the ultrasonic guided wave features obtained from EMATs change consistently and regularly with the charging and discharging states of the battery. The proposed method can be used to analyze the aging of batteries and the inconsistency of electrolyte infiltration inside batteries, which is expected to improve the battery safety.

Hybrid multi-modal NDE sensing system for in-motion detection and localization of rolling contact fatigue damage in rails

This article presents a multi-modal hybrid-probe approach to nondestructive inspection of RCF cracks and damage in rails. A combination of electromagnetic (EM) and ultrasonic testing (UT) techniques are presented, which allows for complementary physics to be utilized to enhance detection and characterization of surface and sub-surface cracks in a non-contact manner at high speeds. A novel integrated design which combines the motion-induced eddy current (MIEC) effect and ultrasonic Rayleigh surface waves generated and detected using electromagnetic acoustic transducer (EMAT) is presented. The hybrid probe was tested at low speeds to demonstrate an increased damage localization capability. This was carried out using a data registration and fusion approach between the sensing modalities. Finally, the capability of MIEC effect at high-speeds is demonstrated. The results show that the hybrid probe has a high potential for in-motion, high-speed damage detection and characterization in the future.

Bottom Crack Detection with Real-Time Signal Amplitude Correction Using EMAT-PEC Composite Sensor.

During electromagnetic ultrasonic testing, it is difficult to recognize small-size bottom cracks by time of flight (ToF), and the lift-off fluctuation of the probe affects the accuracy and consistency of the inspection results. In order to overcome the difficulty, a novel composite sensor of an electromagnetic acoustic transducer (EMAT) and pulse eddy current (PEC) is designed. We use the amplitude of a bottom echo recorded by EMAT to identify the tiny bottom crack as well as the amplitude of PEC signals picked up by the integrated symmetric coils to measure the average lift-off of the probe in real time. Firstly, the effects of lift-off and bottom cracks on the amplitude of bottom echo are distinguished by combining the theoretical analysis and finite element method (FEM). And then an amplitude correction method based on the fusion of EMAT and PEC signals is proposed to reduce the impact of lift-off on the defect signal. The experimental results demonstrate that the designed composite sensor can effectively detect a bottom crack as small as 0.1 mm × 0.3 mm. The signal fusion method can accurately correct the amplitude of defect signals and the relative error is less than ±8%.

Underwater quantitative thickness mapping through marine growth for corrosion measurement using shear wave EMAT with high lift-off performance

Underwater inspection is important to ensure the safety, integrity and functionality of underwater structures. Although numerous conventional methods have been adopted for underwater inspection, successful application of most methods relies on the surface condition of the object, which, however, is typically covered by marine growth. Consequently, routine inspection requires thorough cleaning of marine growth, which is time-consuming and costly. Hence a method which can inspect objects without the need for extensive surface cleaning is necessary. Two methods have the potential to achieve this: pulse eddy current (PEC) and electromagnetic acoustic transducer (EMAT). PEC attains a significant lift-off distance, enabling inspection through marine growth. However, it suffers from high sensitivity to environmental conditions and low inspection accuracy due to ‘relative’ property which means its results are interpreted by comparing received signals to reference values. In contrast to PEC, EMAT provides ‘absolute’ measurements, ensuring precise results in the inspection. But it is limited by a small lift-off distance (<2∼3 mm), rendering it unsuitable for underwater applications with marine growth. Therefore, if the lift-off distance can be enhanced to a specific value, this method may offer a superior solution for underwater inspections. In this paper, a quantitative measurement method is proposed through employing a shear wave EMAT with high lift-off performance. A repelling configuration of magnets is introduced to achieve a significantly improved maximum effective lift-off distance of up to 5 mm in both air and seawater conditions with only 400 Vpp applied. This EMAT is then demonstrated to measure thickness through marine growth, showing excellent underwater performance in quantitative thickness mapping for corrosion inspection.

An Adaptive Noise Reduction Method for High Temperature and Low Voltage Electromagnetic Detection Signals Based on SVMD Combined with ICEEMDAN.

In view of the low signal-to-noise ratio (SNR) of shear wave electromagnetic acoustic transducers (EMAT) in the detection of high-temperature equipment, the use of low excitation voltage (LEV) further deteriorates the detection results, resulting in the echo signal containing defects being drowned in noise. For the extraction of the EMAT signal, an adaptive noise reduction method is proposed. Firstly, the minimum envelope entropy is taken as the fitness function for the Harris Hawks Optimizer (HHO), and the optimal successive variational mode decomposition (SVMD) balance parameter is searched by HHO adaptive iteration to decompose LEV EMAT signals at high temperatures. Then the filter is carried out according to the excitation center frequency and correlation coefficient threshold function. Then, improved complete ensemble empirical mode decomposition with adaptive noise (ICEEMDAN) is used to decompose the filtered signal and combine the kurtosis factor to select the appropriate intrinsic mode functions. Finally, the signal is extracted by the Hilbert transform. In order to verify the effectiveness of the method, it is applied to the low-voltage detection of 40Cr from 25 °C to 700 °C. The results show that the method not only suppresses the background noise and clutter noise but also significantly improves the SNR of EMAT signals, and most importantly, it is able to detect and extract the 2 mm small defects from the echo signals. It has great application prospects and value in the LEV detection of high-temperature equipment.

Debonding inspection with an enhanced miniature EMAT based on multiple pulse echoes

The present paper proposes a non-contact ultrasonic testing method for the debonding inspection of metal-based composite structures, utilizing an improved electromagnetic acoustic transducer (EMAT). The enhanced EMAT incorporates a carbonyl iron powder coil backplate and a small butterfly coil to enhance the detecting ability for interfacial bonding. A two-dimensional finite element model is developed to quantify the effectiveness of the carbonyl iron powder coil backplate on increasing the eddy current density and the magnetic flux density in the specimen. An experimental setup was designed using the Ritec SNAP 5000 and the improved EMATs to examine an aluminium-epoxy resin composite structure. Ultrasonic C-scan images of the specimen's bonding interface were obtained from the experiment. Both simulation and experimental results show that carbonyl iron powder coil backplates can increase the efficiency of the EMATs. By investigating the influence of echo number on debonding detection, it was revealed that employing higher-order echoes and utilizing carbonyl iron powder as the coil backplate can enhance the debonding detection capability. The C-scan imaging results indicate that the utilization of high-order echoes enhances imaging quality, and the employment of high-quality miniaturized EMATs enhances the capability for quantitative analysis of debonding defects.

Design of Staggered Halbach EMAT to Generate SH Guided Wave in Pipe Structures

This research investigates the application of Staggered Electromagnetic Acoustic Transducer (EMAT), mainly focusing on the beam steering capabilities of Shear Horizontal (SH) Guided Waves in pipe structures. As a specific case of EMAT, Staggered EMAT introduces a lateral movement in the magnet rows so that the wave propagation occurs at an angle. A three-dimensional model of double row Staggered Halbach EMAT is developed and a finite element analysis is carried out in an aluminium pipe with high radius to thickness ratio. To obtain better signal-to-noise ratio (SNR), the size of the magnets and the number of magnets in a row are optimized by studying multiple cases. For all the configurations, the in-plane surface displacement is studied keeping the wavelength of the transducer constant. The corresponding frequency is derived from the dispersion curve for SH0 wave mode. The results shows that there is significant increase in the amplitude of the in-plane surface displacement with the increase in magnet height and the number of magnets in a row, ultimately leading to the signal with higher amplitude and better SNR. The study then analyses Staggered Halbach EMATs where the second row of magnets is displaced by the maximum value of half of the wavelength. The interference between the waves generated from the two magnet rows resulted in the directivity change of the guided wave, thereby achieving the steering of the SH wave by the maximum value of 27°. The finding of this study shows the enhanced beam steering capabilities of Staggered EMATs, particularly in the field of pipeline monitoring and can lead to more precise and effective detection of structural defects. Keywords: Staggered Halbach EMAT, Beam Steering, SH Guided Wave, Pipeline Inspection

Design of a Permanent Magnet Electromagnetic Acoustic Transducer (EMAT) for In-Situ Inspection of Metals at high Temperatures

In this proposed research, a permanent magnet longitudinal wave Electromagnetic Acoustic Transducer (EMAT) was designed for In-Situ inspection of metals at high temperatures. A permanent magnet EMAT generates Lorentz force inside metals by the interaction of magnetic fields and eddy currents. As temperature rises, various factors can influence the intensity of the Lorentz force, making it difficult to produce and detect ultrasonic waves. Thus, it is essential to optimize the sensor at ambient temperature before attempting to generate a reliable signal at elevated temperatures. The challenge highlighted has been addressed by optimizing the intensity of static field by varying the parameter like spacing between magnets that are being used. In order to minimize the effects of elevated temperatures, the sensor's stability has been enhanced by the implementation of efficient insulating measures. Furthermore, Finite Element (FE) simulations were conducted under on aluminium sample. These simulation results were then compared to experimental data to validate the efficiency of the designed sensor. Keywords: Permanent magnet, EMAT, Lorentz force, ultrasonic waves, high temperature, static magnetic field intensity.

Electromagnetic Acoustic Transducer and Method for Residual Stress Detection in Conducting Materials

Electromagnetic Acoustic Transducer and Method for Residual Stress Detection in Conducting Materials

Development of a real-time ultrasonic monitoring tool for high-cycle thermal fatigue

Pipe networks within nuclear power plants (NPPs) are susceptible to high-cycle thermal fatigue (HCTF) failures especially in so-called mixing zones where fluids with different thermal and hydraulic properties interact. The 1998 incident at Civaux 1 NPP is a good example of such a failure and its potential consequences. Given the critical impact on safety of these NPP components, a non-invasive method for HCTF progression monitoring in real time is expected to be of great use. Previous ultrasonic monitoring work showed that it is possible to predict the through-thickness temperature distribution and its temporal evolution of a mild steel block to within ±2 °C, relative to a resistance temperature device. These predictions were achieved using time of flight measurements from an ultrasonic transducer placed on the accessible surface with the so-called inverse thermal model (ITM) to invert the data. However, experiments to date have been limited to slow (10 minute) thermal transients at low temperatures (T &lt; 100 °C). Given that HCTF is driven by thermal gradients, the ITM method seems promising to monitor its progression. In this work the performance of the ITM method was investigated under more realistic conditions: faster (1 minute) thermal transients at higher temperatures (≈ 250-300 °C). A special high temperature electromagnetic acoustic transducer (EMAT) and a fast acquisition and inversion methodology were created to collect the data. The measurement setup and the collected data will be presented in this paper.

Structural Design and Optimization of Low-Frequency High-Power Electromagnetic Transducer

Crucial equipment for marine engineering and research, high-power ultra-low frequency sound sources have become necessary with the rapid development of seabed resource exploration, marine environment monitoring, underwater remote target detection, and communication technology. The current ultra-low frequency sound source cannot meet the requirements of practical applications. In this paper, both the finite element method and equivalent circuit method are used to improve the electromagnetic acoustic transducer, focusing on solving the structural design of the functional parts of the transducer, as well as the mechanical, electrical, magnetic parametrization of the transducer and other key technologies. The structural parameters and material parameters in the transducer that affect the final performance response are obtained through the optimization of the genetic algorithm. The results show that the electromagnetic acoustic transducer studied in this paper can emit low-frequency sound waves below 50~Hz, and the maximum sound pressure level reaches 138~dB, which meets the requirements of general low-frequency high-power acoustic wave transducers in practical work.

Spatiotemporal energy regulation strategy for enhancing SNR and spatial resolution in the damage detection with SH0 waves

The fundamental shear horizontal (SH0) wave, which can be generated by electromagnetic acoustic transducers (EMATs), is widely used in the structural health monitoring fields owing to its non-dispersive nature and the ability to detect over long distances. However, current SH0 wave methods hardly achieve the excellent signal-to-noise ratio (SNR) of the echo signals and satisfactory spatial resolution to defects due to the co-restriction between them. To address these issues, a spatiotemporal energy regulation strategy (STERS) is proposed in this paper to optimize energy distribution in the temporal and spatial dimensions. First, spatiotemporal pulse compression technology (STPCT) is proposed to improve both SNR and spatial range resolution for defect detection. Second, a staggered dual-exciter employing two sets of excitation signals is designed to improve the spatial azimuth resolution. Besides, a double sidelobe suppression algorithm (DSSA) is proposed to suppress sidelobe issues arising from the application of STPCT, thereby further improving the performance of STPCT. Finally, multiple simulations and experiments are executed to demonstrate the advantages of the proposed damage detection system. Results show that our methods can achieve comprehensive improvement in SNR, spatial range resolution, spatial azimuth resolution, and sidelobe suppression ability.

Enhancing unilateral EMAT performance through topological optimization of Halbach permanent Magnet arrays

A novel unilaterally excited electromagnetic acoustic transducer (EMAT) is proposed as a solution to address the challenge of weak electromagnetic ultrasonic detection signals being susceptible to interference from clutter noise signals. EMAT employs Halbach permanent magnet array (HPMA) structure and a coil designed based on Huygens superposition principle. This design enables the generation and reception of highly directive Rayleigh surface waves in aluminum plates. To enhance the operational efficiency of EMAT while maintaining a high level of directivity for surface waves, a penalty function is implemented in COMSOL Multiphysics for the topological optimization of EMAT. The objective function in this optimization process is based on covariance (COV) of the magnetic induction intensity. The research results suggest that the homogeneity of the magnetic induction intensity within the coil region is enhanced by 50 % following topological optimization compared to the original design. The energy conversion efficiency of EMAT is enhanced by 5 times compared to traditional designs. The surface wave speed was determined to be 2631 m/s when measured at a frequency of 400 kHz. The value indicates a relative error of 6.37 % in comparison to the theoretical speed. The results indicate that EMAT has the capability to generate high-directional and pure Rayleigh waves.