In offshore reinforced concrete (RC) structures, phenomena of rebar corrosion are widespread, seriously threatening the durability of the structures. However, the issue of entire rebar corrosion process detection, especially for the evaluation of local corrosion states and the scope, is also challengeable. The paper aims at utilizing the nonlinear ultrasonic guided wave (UGW) energy flow to identify reinforcement corrosion level and length during the entire corrosion process in RC structures and establishing a corresponding corrosion evaluation algorithm. Therefore, a corroded rebar with the surrounding concrete cover is simplified into a cylindrical layered structural model. Meanwhile, piezoelectric transducers are used for the actuation and reception of UGWs, and a granular material contact (GMC) model is applied to illustrate the mechanism for generating surface-contact-induced nonlinear components in scattering waves. Then, the propagation behavior of the nonlinear UGWs is analyzed by regarding the corrosion layer as a secondary sound source changing the wave energy flow. A corrosion evaluation algorithm based on the GMC model is established and validated by both experiment and finite element (FE) analysis. The results show that for a harmonic UGW excitation signal, the periodic relationship between the second-order nonlinear coefficient of received signal and the corrosion length is found in which the period is associated with the difference (kd) of 2 times of fundamental frequency wave number (2 kω) and double frequency wave number (k2ω). Particularly, as kd trends to zero, a degraded linear relationship is found for establishing the corrosion length evaluation algorithm with the relatively high evaluation precision and convenient evaluation technique.
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