Ultrasonic Testing Method Research Articles

Defect classification of composite materials using transfer learning methods

ABSTRACT Nowadays, composite materials have become prevalent across various sectors, particularly finding usage in large-scale applications such as spaceships, automobiles, and aircrafts. The accurate detection of the defects in these materials is crucial, yet traditional methods often rely on human inspection, which is susceptible to errors. Recent advancements in machine learning have enabled defect detection using ultrasonic non-destructive testing methods. This paper introduces a new dataset named UNDT, which is obtained from the scans of 60 different composite materials, generating a total of 1150 images depicting both defective and non-defective areas. Several transfer learning methods are applied on the newly introduced UNDT dataset as well as the publicly available USimgAIST ultrasonic dataset. Comparative performance assessments illustrate the significance of utilising the transfer learning approach for defect classification on ultrasonic inspection images. Furthermore, the research emphasises the substantial benefits of employing these transfer learning methods. Notably, the DenseNet121 and VGG19 models achieve the highest accuracy rates, with 98.8% and 98.6% on the UNDT and USimgAIST datasets, respectively.

Research on ultrasonic testing method for tangential contact stress based on equivalent medium theory

As a weak link, the joint surface of machine tools directly affects the stiffness and machining accuracy of the entire machine tool. However, obtaining the distribution of contact stress is a key problem that urgently needs to be solved in exploring the mechanical properties of joint surface connections. In this paper, a tangential contact stress ultrasonic testing method based on the equivalent medium theory is proposed, providing data support for accurately characterizing the contact state of the joint surface. A virtual material model of rough contact interface based on fractal theory is established to explore the coupling relationship between the propagation speed of ultrasonic critical refracted longitudinal waves, the tested object’s material parameters, and stress. Moreover, the expression of the equivalent material parameters of the ultrasonic critical refracted longitudinal wave propagation layer with stress variation is derived. An ultrasonic acoustic time difference model considering changes in contact surface material parameters is constructed based on the principle of acoustic elasticity of ultrasound. Furthermore, a critical refractive detection model for longitudinal wave’s tangential contact stress is established based on equivalent medium theory. Experimental specimens and stress detection plans are designed, and the tangential contact stress of the specimens is measured based on the division of surface grids. The equivalent stress value of each node is calculated based on the von Mises stress by measuring the stress in the X/Y direction. In addition, a shear stress distribution cloud map of the contact surface is drawn. Finally, the accuracy of the detection results is confirmed by combining theory, simulation, and experimental methods. The proposed tangential contact stress detection method based on critical refractive longitudinal waves is significant for low-stress assemblies.

Analysis of the Remaining Life Assessment of Fb-8701c Spherical Tank based on Thickness Measurement Data with Ultrasonic Testing Method

This remaining life assessment assessed the thickness and corrosion rate characteristics of A516 Grade 70 carbon steel, a material widely used in the fabrication of pressure vessels and boilers, including spherical tanks. The material was evaluated through ultrasonic non-destructive testing, with the aim of determining the minimum thickness and corrosion rate, based on field data collected by the inspector. The data was then analyzed to determine the minimum allowable thickness and estimate the remaining life of the pressure vessel based on API 510 standard. The study results showed that all components examined were within safe limits for use, above the required thickness (actual thickness > required thickness). The calculation of the highest corrosion rate is on the Top Head Plate 7 component, which is 0.067 mm/year, so this component has the shortest remaining life, which is 54.06 years. This study also calculates the maximum allowable working pressure (MAWP) value which is a reference to ensure the safety of pressure vessels when operated. The working pressure when operated must not exceed the calculated MAWP value. The calculated MAWP value is in the range of 6.99 to 8.12 psi.

In-situ detection of electrolyte defects in lithium-ion batteries using ultrasonic imaging and analysis of formation patterns

The urgent necessity for enhanced cycling performance in lithium batteries is paramount for electric vehicles to attain broader economic advantages. However, prolonged usage and cycling often lead to electrolyte de-wetting within the battery, posing a significant risk to battery safety and lifespan reduction. A thorough understanding of the mechanisms underlying electrolyte de-wetting is pivotal for the development of long-lasting batteries. This study employs an ultrasonic non-destructive testing method to investigate changes in the internal electrolyte during battery operation. Analysis of the results found that during to the relatively higher current density and temperature near the tabs, electrolyte de-wetting is more prone to occur in these areas, with defects being more severe at the positive electrode compared to the negative electrode. Finally, these issues are addressed to provide reasonable recommendations for future battery design and optimization.

Profiling the thermal damage gradient in concrete using linear and non-linear ultrasonics

Processes such as carbonation and thermal damage result in a depth-dependent variation in concrete mechanical properties, which are typically characterized by invasive sampling and destructive testing. In this study, several ultrasonic testing methods are employed to nondestructively measure gradients in elastic properties within concrete and mortar slabs, induced by varying amount of exposure to elevated temperatures. The slabs are subjected to two distinct heat exposures, carefully chosen to create different gradients within the first few centimeters below the surface. The first exposure scenario following the ISO fire standard led to superficial damage. Deeper damage was achieved with radiant panels. We use linear and non-linear ultrasonic testing, with the aim of characterizing the resulting property gradients including refracted P-waves, analysis of surface wave dispersion and higher harmonic generation. Additionally, we employ NRUS (nonlinear resonant ultrasound spectroscopy) to test slices extracted from the different depths within the slabs. The ultrasonic test results are benchmarked and interpreted in relation to a suite of other multiphysical measurements (resistivity, capacity, temperature). This work represents a first crucial step towards the development of a new method for measuring gradients of nonlinear elastic properties within concrete through nondestructive ultrasonic testing.

Ultrasonic Non-Destructive Testing of Accelerated Carbonation Cured-Eco-Bricks

This study aimed to investigate the behavior of accelerated carbonation-cured laboratory specimens using the ultrasonic non-destructive testing (UNDT) method and compare the results with the destructive testing (DT) method. The materials used in the study included a blend of lime kiln dust and ground granulated blast furnace slag (LKD-GBFS) wastes, natural fine aggregate (sand), and alternative fine aggregates from waste tires. The chemical analysis of the LKD and GBFS samples highlighted them as suitable alternatives to OPC, hence their utilization in the study. A 60:40 (LKD-GBFS) blending ratio and a 1:2 mix design (one part LKD-GBFS blend and two part sand) was considered. The natural fine aggregate was partially replaced with fine waste tire rubber crumbs (TRCs) in stepped increments of 0, 5, and 10% by the volume of the sand. The samples produced were cured using three curing regimens: humid curing (HC), accelerated carbonation curing (ACC) with no water curing (NWC) afterwards, and water curing after carbonation (WC). From the results, an exponential model was developed, which showed a direct correlation between the UNDT and DT results. The developed model is a useful tool that can predict the CS of carbonated samples when cast samples are unavailable. Lastly, a total CO2 uptake of 15,912 g (15.9 kg) was recorded, which underscores ACC as a promising curing technique that can be utilized in the construction industry. This technique will bring about savings in terms of the time required to produce masonry units while promoting a change in the basic assumptions of a safer and cleaner environment.

Enhancing Time-of-Flight Diffraction (TOFD) Inspection through an Innovative Curved-Sole Probe Design

Time-of-Flight Diffraction (TOFD) is a method of ultrasonic testing (UT) that is widely established as a non-destructive technique (NDT) mainly used for the inspection of welds. In contrast to other established UT techniques, TOFD is capable of identifying discontinuities regardless of their orientation. This paper proposes a redesign of the typical TOFD transducers, featuring an innovative curved sole aimed at enhancing their defect detection capabilities. This design is particularly beneficial for thick-walled samples, as it allows for deeper inspections without compromising the resolution near the surface area. During this research, an evaluation consisting in simulations of the ultrasonic beam distribution and experimental tests on a component with artificially manufactured defects at varying depths has been performed to validate the new design. The results demonstrate a 30 to 50% higher beam distribution area as well as an improvement in the signal-to-noise ratio (SNR) resulting in a 24% enhancement in the capability of defect detection compared to the traditional approach.

A novel bidirectional LSTM network model for very high cycle random fatigue performance of CFRP composite thin plates

This study proposes a novel Double-layer Bidirectional Long Short-Term Memory (BiLSTM) neural network model, shorted as TDA-BiLSTM, which integrates Transfer learning and Attention mechanisms. The model aims to predict the fatigue life of carbon fiber reinforced polymer (CFRP) thin plate structures subjected to very high cycle random vibration fatigue loads. Distinct from conventional servo-hydraulic and ultrasonic fatigue testing methods, this research pioneers the use of a vibration table for very high cycle fatigue (VHCF) testing to fill the gap in the field. By training and validating data across various life ranges, the TDA-BiLSTM model demonstrates significant advantages in training speed and predicting accuracy. Its bidirectional structure and attention mechanism effectively capture complex patterns and long-term dependencies in sequence data. Experimental results indicate that the TDA-BiLSTM model achieves significantly lower Mean Absolute Error (MAE) and Root Mean Square Error (RMSE) compared to Long Short-Term Memory (LSTM) and Long Short-Term Memory with Transfer learning (Tr-LSTM) models across different life ranges on the ε-N curve, indicating higher accuracy and stability in strain life prediction tasks. Additionally, an analysis of typical damage areas using Scanning Electron Microscopy (SEM) reveals the failure mechanisms of CFRP plates under very high cycle vibration fatigue loads.

Simulation and Experimental Research of V-Crack Testing of Rail Surfaces Based on Laser Ultrasound

Rail surface cracks are widespread damage that can lead to uneven surfaces of railheads and affect traveling safety. Non-destructive testing is needed to inspect rails regularly to ensure the normal operation of railroads. This paper proposes a laser ultrasonic testing method combining variational mode decomposition and diffractive Rayleigh wave time-of-flight to detect tiny cracks on the rail surface quantitatively. The finite element method was combined with experiments to simulate and experimentally investigate cracks of different sizes numerically. In the numerical simulation, the location of the crack was determined by B-scan. Afterward, the interaction between various types of ultrasound and cracks was comparatively analyzed, and the crack size was quantitatively characterized using useful information from the ultrasound signals. The results show that the time-of-flight method can detect arbitrary cracks with low error. Therefore, the experimentally acquired ultrasound signals used the time difference between the diffracted Rayleigh wave and other ultrasound waves to detect the crack information quantitatively. The variational mode decomposition method was used to separate the ultrasonic signals and extract the best surface wave modes to improve the signal-to-noise ratio. The results show that the combination of variational mode decomposition and time-of-flight method can effectively detect the size of cracks.

Non-destructive ultrasonic testing for identifying concealed weapons and analyzing internal chemical substances

The management of unknown weapons obtained from warfare, military operations, and terrorist situations requires a series of nondestructive testing processes. This management process, which is aimed at collecting information on the nature of the weapons, encompasses identification, processing, transportation, and storage of the obtained weapons. A lack of identification marks in acquired ammunition may indicate the potential presence of a chemical weapon. Therefore, nondestructive evaluation methods have been employed to identify unknown weapons. However, these methods rely on neutron- and radiation-based analyses, which require radiation-handling experts and specific protective facilities. Consequently, their application in this field is challenging. Herein, a nondestructive ultrasonic testing method, which can identify substances inside unknown weapons and optimize the verifiability of the state of the ammunition, was employed as an alternative method to overcome these limitations. The experimental system enabled quantitative and qualitative analyses of the internal chemicals by analyzing the time difference in acquiring the signals, particularly when the results indicate that the internal substance is a liquid. The results of this study can serve as a basis for advancing the application of ultrasonic testing as a viable and efficient approach for managing unknown weapons.

Full-size experimental investigations on planetary gear journal bearings in high-power wind turbines

Abstract To satisfy the large-scale and high-power demands of wind turbines, planetary gear journal bearings (PGJBs) have been applied in large wind turbine gearboxes (WTGs), as an alternative to traditional rolling bearings, due to their higher reliability and smaller size. To simulate the actual lubrication behaviors of PGJBs and investigate their hydrodynamic performance, a full-size test rig for PGJBs was built in this paper. A multi-parameter detection system coupled with the ultrasonic testing method was developed. Four ultrasonic piezoelectric elements, eight thermistors, two pressure transducers, and one torque sensor were used to obtain the film thickness, oil temperature, oil pressure, and friction torque data of the test PGJB. The rated condition experiment was conducted to investigate the variation of measured lubrication performance with the operating time. Three-dimensional predictions of oil film pressure, temperature, and thickness were presented to analyze the steady-state lubrication characteristic at the rated condition. Moreover, a series of steady-state experiments were also carried out to simulate the normal operations of the test PGJB at different conditions. And the measured results were verified by the numerical predictions. The influence of rotational speed, input load, oil supply temperature, and oil supply flow on the hydrodynamic performance of the test PGJB were explored.

Interface stiffness identification of rough and weak bonded interface using developed ultrasonic reflection phase derivative spectrum

The thickness and interface roughness of coatings both affect the interface bonded quality. Existed ultrasonic testing methods based on traditional phase screen approximation or spring model assumption are difficult to simultaneously identify the interface roughness and stiffness of coating. This paper, a new method for integrated identifying coating thickness, interface roughness, and interface stiffness using developed ultrasonic reflection phase derivative spectrum (URPDS) is proposed. A phase-screen-approximated spring-model (PSASM) for ultrasound vertically propagating into rough and weak bonded interface is constructed. On basis of PSASM, a URPDS of coating/substrate structure is developed for identifying the interface stiffness and other parameters of coated parts. Cross-correlation analysis is used to eliminate the phase deviation of URPDS introduced by reference signal and initial phase of tested signal. Sensitivity analysis is used to determine the high-sensitivity regions of URPDS to interface roughness and interface stiffness. Genetic algorithm optimization is used to achieve integrated identification of coating thickness, interface roughness, and interface stiffness. The rationality of PSASM is verified through numerical simulation using a series of coating/substrate models with rough and weak bonded interface, and the relationship between the high-sensitivity regions and the high-precision measurement ranges of interface roughness Rq and interface stiffness Kn is clarified. Ultrasonic experiments are implemented on Nickel-coating samples and coated parts using plane wave probe. The coating thickness, interface roughness, and interface stiffness could be identified accurately, which shows that the proposed URPDS method can identify the interface stiffness of rough contacted dissimilar media or coated parts with rough interface.

Ultrasonic testing method for impeller brazing defects with refraction wave perpendicular to brazing surface and angle amplitude compensation

Abstract There are blind areas in ultrasonic brazing defect detection, due to the non-parallel brazing surface and outer surface for many components including impeller. In this paper an oblique incident ultrasonic testing method with a refraction wave perpendicular to brazing surface is proposed. Meanwhile, an incident angle amplitude compensation is implemented to decrease the influence of the defect echo amplitude difference caused by oblique incidence and unify the sensitivity of different scanning positions. The compensation curve based on the theoretical curve of echo energy at different incident angles is optimized with iteration of actual measured defect echo amplitude. In order to prove the need for ultrasonic testing method with a refraction wave perpendicular to brazing surface, bottom surface echo test for conical samples is operated. In addition, with the method proposed in this paper, scanning image of impeller sample with the same detection sensitivity is obtained successfully. Testing results suggest that in relation to old method with incident wave perpendicular to the outer surface, the method proposed in this paper can solve the blind area problem effectively.

Study on ultrasonic lamb wave testing technology of honeycomb sandwich structures

Abstract Honeycomb sandwich composite panels have complex structures, large sizes, many types of defects, and significant sound attenuation, which lead to low efficiency and poor sensitivity of ultrasonic non-destructive testing. In the study, a non-linear ultrasonic lamb wave testing technique for honeycomb sandwich composite panels is proposed. Firstly, the anisotropic propagation characteristics and modal structure of lamb waves in honeycomb sandwich composite panels are analyzed, and the lamb wave modes with non-linear ultrasonic accumulation are excited. Secondly, the data extraction method and imaging algorithm of non-linear ultrasonic lamb wave imaging testing are proposed. Finally, an enhanced imaging algorithm is proposed to improve image quality based on the sliding window algorithm. Based on the comparative analysis of air-coupled ultrasonic testing images and metallographic tests, it can be seen that non-linear ultrasonic lamb wave testing signals can be used to characterize the damage distribution characteristics of honeycomb sandwich composite panels, display debonding and weak debonding defects, and have the advantages of being able to perform on the same side testing and high efficiency, which can be used for non-destructive testing of honeycomb sandwich composite panels.

Assessment of Weld Microstructure Through Sound Velocity Measurements for Power Plant Applications

This research study employed an immersion-based micro-resolution ultrasonic velocity measurement technique (MUVT) to evaluate Grade 91 (9Cr-1Mo-V) steel welds. This process utilized a 20 MHz focused ultrasonic beam with a spot size of 250 µm, a 6 µm laser vibrometer spot size for detection, and an automated 3-axis raster scanner to accurately collect ultrasonic velocity data from two Grade 91 steel welds fabricated using cold metal transfer (CMT) and flux-cored arc welding (FCAW) processes. By analyzing the MUVT data, the Poisson’s ratio (υ) and modulus of elasticity (E), which are important mechanical properties for weldments, were calculated. The correlation between mechanical properties and ultrasonic velocity was examined. The results indicated that longitudinal ultrasonic velocity could effectively identify base metal, heat-affected zone (HAZ), and weld metal areas, showing a strong correlation with hardness. In particular, the distinctive V-shaped dip in velocity and hardness data across the HAZ areas of both samples highlighted changes in the microstructure of creep strength–enhanced ferritic steel welds. Importantly, the immersion-based MUVT demonstrated high accuracy in small sections of the weld, surpassing the conventional contact ultrasonic testing method in spatial resolution detection.

Research on Phased Array Ultrasonic Imaging Method Based on Time Reversal Theory

Abstract With the wide application of additive manufacturing components and composite materials, it is of great significance to detect defects with non-destructive testing methods in the material manufacturing process and in service. Due to the strong attenuation and inhomogeneity characteristics, it is inefficient and poor imaging results to detect its internal defects by conventional ultrasonic testing methods. To improve the detection accuracy, this paper proposes an improved imaging algorithm with time reversal-total focusing method (TR-TFM) imaging technology to improve the defects detection in strongly attenuating materials. The experimental results show that the amplitude of the defect signal is increased by 8.30 dB, and compared with total focusing method (TFM), the diameter of the detected defect with TR-TFM imaging is increased from 1.20 mm to 1.60 mm, which is more adjacent to the accurate size. Meanwhile, with the sparse matrix based on FMC data, TR-TFM could obtain the same image quality with the approximate time of TFM imaging.

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.

Laser ultrasonic testing of defects in milling groove brazed joints of thrust chamber

This paper presented a new approach for noncontact inspection of defects in milling groove brazed joints of thrust chamber with laser ultrasonic testing method and synthetic aperture focusing technique (SAFT). Firstly, laser ultrasonic testing methods for milling groove brazed joints of thrust chamber was studied. Subsequently, numerical models were constructed to analyze the influence of defects on laser-excited signals. The analysis revealed that the brazed defects caused internal waves to reflect on the rib surface, manifesting as defect echo signals preceding the outer wall echo. Through scanning setting, the obtained SAFT images illustrate the presence of the defect directly and clearly. Furthermore, an experimental system was established to detect and image artificial defects with different degrees of weld leakage. The experimental results are consistent with simulation results, validating the capability and effectiveness of the testing and imaging method. In general, the proposed laser ultrasound method offers inherent advantages of non-contact detection with high resolution and precision, and it is easy to achieve fast and automated scanning of large and complex structures like thrust chambers, demonstrating its potential for enhancing the safety and reliability of liquid rocket engines.

A Water Environment-Based Simulated Method for Ultrasonic Testing of Slag Inclusion Weld Defects Based on Improved VMD.

The identification of slag inclusion defects in welds is of the utmost importance in guaranteeing the integrity, safety, and prolonged service life of welded structures. Most research focuses on different kinds of weld defects, but branch research on categories of slag inclusion material is limited and critical for safeguarding the quality of engineering and the well-being of personnel. To address this issue, we design a simulated method using ultrasonic testing to identify the inclusion of material categories in austenitic stainless steel. It is based on a simulated experiment in a water environment, and six categories of cubic specimens, including four metallic and two non-metallic materials, are selected to simulate the slag materials of the inclusion defects. Variational mode decomposition optimized by particle swarm optimization is employed for ultrasonic signals denoising. Moreover, the phase spectrum of the denoised signal is utilized to extract the phase characteristic of the echo signal from the water-slag specimen interface. The experimental results show that our method has the characteristics of appropriate decomposition and good denoising performance. Compared with famous signal denoising algorithms, the proposed method extracted the lowest number of intrinsic mode functions from the echo signal with the highest signal-to-noise ratio and lowest normalized cross-correlation among all of the comparative algorithms in signal denoising of weld slag inclusion defects. Finally, the phase spectrum can ascertain whether the slag inclusion is a thicker or thinner medium compared with the weld base material based on the half-wave loss existing or not in the echo signal phase.

Ultrasonic dynamic plane wave imaging for high-speed railway inspection

The detection of internal defects within railway tracks stands as a critical aspect of ensuring transport security, given its potential to precipitate severe accidents. Phased array ultrasonic testing methods have gained extensive usage in rail inspection owing to their remarkable precision and expansive coverage. Traditional ultrasonic inspection techniques typically require either a fixed relative position between the transducer and the specimens or a gentle movement of the transducer to beamform. However, the unavoidable vibration stemming from the vehicle–rail coupled interactions often results in time-variant media, significantly impacting the beamforming. This paper presents a refined wavenumber-domain plane wave imaging technique tailored to enable real-time dynamic imaging, specifically accommodating the vertical vibrational movement of the transducer. Real-time calculation of the transmission focal law is achieved by numerical fitting. The wavenumber-domain technique is utilized to realize real-time accurately reconstructed images. The efficacy of the proposed method is assessed through simulations and experiments performed on a convex cylindrical specimen and a rail head sample, respectively. It can be seen that this approach can achieve a frame rate of 83.3 fps with a pipeline architecture in this study, demonstrating the capability to reconstruct images in vibrating environments, such as during the high-speed inspection of railways.