Ultrasonic Inspection Techniques Research Articles

Development of ultrasonic phased array technique for inspection of fir-tree type turbine blade root and disc-rim in nuclear power plant

Development of ultrasonic phased array technique for inspection of fir-tree type turbine blade root and disc-rim in nuclear power plant

In situ monitoring of defects in steel structures using a robot‐assisted ultrasonic inspection technique

AbstractIncidents in extreme environments can bring unprecedented consequences that would endanger the lives of many humans. Real‐time and early detection of cracks and defects in the steel used for the construction of industrial sites can bring many benefits to remote operators and site managers. Although different methods and systems have been proposed in the past, they are not suitable for real‐time fault detection or long‐term operation in harsh environments. Therefore, this paper proposes a low‐power robotic platform with a magnetic actuator mechanism which is capable of wireless inspection of steel structures using the ultrasonic method. The proposed magnetic motion uses the inertia force generated by the piston vibration and the difference in frictional force during movement. The paper evaluates the performance of the steel structure defect detection system from four different perspectives: sensing principle, wireless communication network, driving part, and power supply.

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.

Systematic Evaluation of Ultrasonic In-Line Inspection Techniques for Oil and Gas Pipeline Defects Based on Bibliometric Analysis.

The global reliance on oil and gas pipelines for energy transportation is increasing. As the pioneering review in the field of ultrasonic defect detection for oil and gas pipelines based on bibliometric methods, this study employs visual analysis to identify the most influential countries, academic institutions, and journals in this domain. Through cluster analysis, it determines the primary trends, research hotspots, and future directions in this critical field. Starting from the current global industrial ultrasonic in-line inspection (ILI) detection level, this paper provides a flowchart for selecting detection methods and a table for defect comparison, detailing the comparative performance limits of different detection devices. It offers a comprehensive perspective on the latest ultrasonic pipeline detection technology from laboratory experiments to industrial practice.

Ultrasonic assessment of aging in lithium metal pouch cells

Lithium metal anodes are prone to non-uniform lithium plating that can lead to dendrite formation, internal short circuits, and catastrophic ignition. This type of structural defect is not captured by battery management systems, prompting the need to advance nondestructive evaluation (NDE) techniques that are suitable for periodic monitoring of the internal structure. An ultrasonic inspection technique is evaluated here as a means of identifying flaws and irregular lithium plating that can be a precursor to dendrite formation and, ultimately, battery failure.Lithium metal pouch cell batteries were aged through electrochemical cycling at a range of moderate constant-current charging and discharging rates. They were inspected intermittently using a tailored local ultrasonic resonance spectroscopy (LURS) approach that measures the local through-thickness resonances of the battery as an indicator of the underlying structure. LURS results showed clear structural resonances in cells in the range of 3–7 MHz, which shifted significantly to lower frequencies as batteries aged. In addition to point measurements, scanning LURS measurements were implemented to map resonance frequencies over the electrode surface. These resonance maps revealed spatial variations in structure that developed during aging and showed better contrast to structural variation than achieved using conventional amplitude-based c-scans of the specimens.NDE results from pouch cell measurements were compared to a destructive physical analysis of the electrode structures using scanning electron microscopy (SEM). The SEM results showed differences in the end-of-life lithium anode structure at different charge rates. The results of this study show the capability of LURS as a means for identifying changes in battery structures during aging and establish resonance trends that may be applied in future work for prognostic modeling of batteries in service.

Ultrasonic Non-Destructive Testing on Fast-Charging Lithium-Ion Battery’s Capacity Fading

Fast charging technology provides a solution to the issue of charging time for power supplies with long life requirements. However, it will shorten the charging period while also hastening the power battery’s capacity degradation, reducing its service life. The ultrasonic inspection technique has been widely used for the internal structure detection and reaction process characterisation of lithium-ion batteries because of its nondestructive testing properties. This paper presents a method for monitoring the capacity attenuation of a fast-charging battery by calculating the ultrasonic attenuation coefficient α. The experimental findings indicate that the battery’s capacity is more vulnerable to lithium plating during high-rate charging. The parameter α can be employed to illustrate the energy dissipation characteristics of sound as it propagates through the electrode. Moreover, the inhomogeneous ageing of battery electrode material is observed and quantified based on the differences in acoustic signals, which provides new insights into battery health management and uneven ageing assessment.

Ultrasonic metrics for large-area rapid wrinkle detection and classification in composites

Due to their high strength-to-weight ratio, composite materials are now in use in many high-stress applications, particularly where light weight is also a requirement. In these situations, the detrimental knock-down in mechanical strength due to an out-of-plane wrinkle defect can have serious consequences and is the reason for a requirement to rapidly detect any such wrinkles at manufacture. Unfortunately, current ultrasonic inspection techniques used for quality control at manufacture are not sensitive enough to detect these wrinkles above coherent structural noise variations. This paper exploits the ply resonance that is a characteristic of multi-layer structures to generate two new metrics for both detection and classification of out-of-plane wrinkles, due to their perturbations of the ply spacing. These can be measured at every location on a structure using the instantaneous frequency, which is the rate of change of phase in the pulse-echo ultrasonic response. The proposed two new metrics for detection and classification of wrinkles are mean spacing and spacing difference and they can be applied to each waveform in real time, as it is acquired. Use of an analytical model to predict the ultrasonic response of the structure has allowed an understanding of how these metrics will be affected by various wrinkle types and how they can not only detect wrinkles but also classify the type of wrinkle and provide an approximate indication of severity. Three main types of wrinkle are considered: classic wrinkles near the mid-plane of a structure, back-surface wrinkles formed from a resin bulge near the back of a structure and folded wrinkles where several plies can be folded over completely in the bulk of the structure. Both simulations and experimental results demonstrate the effectiveness of these metrics on various types of structure, including carbon-fibre and hybrid carbon/glass-fibre composites with a range of ply thicknesses and wrinkle types.

Near-surface defect detection in additively manufactured components using laser induced phased arrays with surface acoustic wave crosstalk suppression

In-process inspection of the additive manufacturing process requires a technique that can provide reliable measurements given the extreme operating environments, the small size of the defects and the cyclic melting and heating of the material, caused by subsequently deposited layers. A remote and couplant-free ultrasonic inspection technique using bulk waves that can image near-surface defects could address these in-process inspection requirements. Laser induced phased arrays (LIPA) generate and detect ultrasound based on laser ultrasonics principles, while the array is synthesised in post-processing. However, when using LIPAs for inspection, the surface acoustic waves (SAWs) interfere with the bulk wave modes giving rise to crosstalk and artefacts, which makes near-surface defect imaging difficult. This work experimentally validates and compares five techniques for SAW suppression: amplitude thresholding, mean waveform subtraction, principal component subtraction, frequency-wavenumber filtering, and phase coherence imaging. SAW suppression is demonstrated in ultrasonic images of transverse waves based on 71-element LIPA data synthesised on a Ti-6Al-4V directed energy deposition-arc (DED-Arc/Ti6Al4V) sample with a ∼1 mm diameter side drilled hole, located at ∼4 mm below the inspected surface. The reported results show that the principal component subtraction approach achieved the highest ‘signal-to-crosstalk ratio’ improvement of 16 dB, while successfully suppressing the SAW.

Benefits of Non-Destructive Evaluation and Probabilistic Damage Tolerance Cosimulation for Fracture Risk Reduction

In the context of the damage tolerance approach used to drive aircraft maintenance operations, it is essential to demonstrate the reliability of NDE inspections in detecting structural damage especially for additively manufactured components since this process produces components that may introduce material anomalies at any location within a component. The Probability Of Detection curve (POD) that links the probability to detect a detrimental flaw to its size is generally used as a key indicator for that purpose by giving the maximum flaw size that a NDE process can miss with a given level of probability and confidence. This information can then be used along with other inputs such as component geometries, mechanical properties, constraints, service and residual stresses and damage evolution speed to assess fracture risk and then adapt maintenance scenarios to optimize safety and component service life. NDE reliability and risk assessment are based on statistical indicators that need a large amount of data to provide reliable metrics. It is difficult to obtain such indicators using a purely empirical approach that is based on physical trials and measurements as it may involve many mock-ups and costly processes. Simulation tools can achieve this goal via their ability to include and precisely monitor many parameters as well as high computing capacities that are now available. The work presented in this paper involved cosimulations performed between the DARWIN® probabilistic damage tolerance software and the CIVA NDE simulation software. DARWIN computes fracture risk levels throughout a component, while CIVA can efficiently provide Probability Of Detection curves at different locations in a component and for various NDE methods. The presented application deals with a titanium gas turbine engine impeller disk and involves an Ultrasonic NDE inspection technique. It appears to be a very interesting approach to connect together NDE and Fracture mechanics simulations, two disciplines that generally work on their own. Indeed, DARWIN helps the user to determine detrimental flaw types, locations and sizes which are key inputs to develop an effective NDE inspection method. CIVA can provide location-specific POD curves that enable DARWIN to quantity the effect of dedicated NDE on potential risk reduction. This highlights the importance of NDE simulation for safety and helps to identify potential changes in the physical NDE process and the maintenance cycle that provide the best compromise between detection performance and cost.

Noncontact nondestructive ultrasonic techniques for manufacturing defects monitoring in composites: a review

Composite materials are widely used in most industries due to their high specific strength, specific stiffness, and their relatively lighter weight compared to other traditional materials. However, the presence of defects arising from manufacturing processes or during service loads can make these structures more susceptible to a diminished performance. Furthermore, the former defects are inevitable in composite structures, but they can be reduced. Each type of defect requires specific inspection techniques and configurations. In this work, a review of the different types of composites manufacturing processes and their corresponding resultant defects is presented with the various nondestructive evaluation techniques employed for these defects’ characterization. The emphasis of this paper is on ultrasonic inspection and detection techniques for they present high sensitivity to surface/subsurface discontinuities, superior depth of ultrasonic penetration for flaw detection, feasibility on large scales, and instantaneous and detailed images production. Notably, noncontact ultrasonic testing techniques are also reviewed, air-coupled techniques in specific, and highlighted as a fine alternative to conventional contact inspection systems as they reduce the restrictions that coexist with the use of couplants. Moreover, these ultrasonic testing techniques are summarized to show the latest research progress achieved in the field of air-coupled ultrasonic inspection systems for manufacturing defects’ monitoring in composite structures including delamination, porosity, dryness, waviness, and resin lack/excess. Finally, we highlight the type and central frequency of the transducers and experimental results present in literature and obtained in terms of both detection and size of the defects.

Ultrasonic examination of a thin, textured metal plate with Penrose tile structure consisting of pitched indentations

A feasibility study is presented on the experimental application of ultrasound to examine rolled stainless steel plates having equidistant surface textures in two directions in the form of Penrose tiles. The specific problem of interest is investigating surface profile quality in terms of its equidistance and depth to monitor the manufacturing process. The goal is to eventually replace current time-consuming optical examination procedures with a reliable and rapid ultrasonic inspection technique. Two practical experimental setups are discussed and compared in this work: examining frequency spectra obtained from normal incidence pulse-echo measurements, and those obtained at Laue angle incidence. A thorough survey of ultrasonic methods precedes the experimental results to investigate such surfaces from a historical perspective.

Ultrasonic Inspection Technique for Welded Joints Obtained by Spot Friction Stir Welding

Ultrasonic Inspection Technique for Welded Joints Obtained by Spot Friction Stir Welding

Imaging Concrete Structures with Ultrasonic Shear Waves—Technology Development and Demonstration of Capabilities

Since 1987 when dry-point-contact (DPC) transducers were invented in the USSR, ultrasonic shear wave devices based on those transducers have been commercialized and have become one of the most effective technologies for imaging concrete. That said, the objectives of this paper are (1) to provide a brief review of the historical development of these powerful devices and (2) to provide a comprehensive assessment of their capabilities in imaging internal entities and structural defects. Regarding the former, the paper presents the context that gave birth to DPC technology and different generations of ultrasonic shear wave devices for concrete inspection. For the latter, one of the state-of-the-art ultrasonic shear wave devices (MIRA 3D) was used to collect data on concrete specimens with different built-in flaws/defects. Those data are then visualized with a commonly used data processing algorithm, the so-called synthetic aperture focusing technique (SAFT). Finally, based on the resulting images, the capabilities of the device are discussed in detail for each concrete imaging problem. A main limitation of ultrasonic shear wave technique for concrete inspection is that it requires a significant amount of time and effort for data collection.

Imaging features of different defects in metals using laser ultrasonic techniques

Different types of defects such as pores, porosity, cracks in different directions, have various impact on the load bearing capacity and fatigue strength of metal components used in the field of aerospace, rail transportation, electrical equipment, etc. Therefore, feature recognition and classification of defects contribute greatly to the performance evaluation of the metal components. In this paper, the imaging features of six typical defects in metals were obtained by using laser ultrasonic (LU) scan inspection techniques. First, the numerical models of LU inspection of different defects were established based on the discontinuous Galerkin finite element method (dG-FEM) in COMSOL/Multiphysics. Then, multiple groups of FE simulations were carried out. The generation and receiving lasers were moved along the scanning direction according to a fixed step during the simulation. All the simulated A-scan signals were stacked up and plotted in the B-scan and D-scan maps. At last, six samples with different artificial defects were manufactured for the LU inspection experiment. The defect imaging features in the experimental B-scan maps are consistent with the numerical results. Besides, the mathematical calculation methods of defect position, dimension and orientation were put forward.

Nondestructive analysis of corrosion in ageing hardened AA6351 aluminium alloys

Aluminum alloys have been chosen over other lightweight structural materials because of their advantages regarding strength, long-term durability, and low cost. Aluminum comes under the category of highly reactive metals, where an inherently stable oxide layer can protect against aggressive corrosive conditions. Therefore, this research investigated the application of the ultrasonic nondestructive technique for inspection and monitoring of corrosion behavior of AA6351 heat-treated aluminum alloys. The samples were artificial age hardened at five different conditions. The complementary engineering experiments for materials evaluation included hardness, X-ray diffraction and salt spray tests. Overall findings showed correlations between ultrasonic and destructive data representing a fast, versatile and reliable inspection technique. Furthermore, findings show a significant correlation (>99%), thus supporting the benefits of the multiparametric ultrasonic test for heat treatment inspection and quality control of lightweight structural materials.

Comparative Analysis of Ultrasonic NDT Techniques for the Detection and Characterisation of Hydrogen-Induced Cracking.

The article is devoted to the investigation of ultrasonic inspection techniques suitable for detecting hydrogen-induced cracking (HIC) and a high-temperature hydrogen attack (HTHA), which are of great importance in petrochemical and refinery industries. Four techniques were investigated: total focusing method (TFM), advanced velocity ratio (AVR) measurement, advanced ultrasonic backscatter technique (AUBT) and time of flight diffraction method using ultra low angle ultrasonic transducers (TULA). The experimental investigation has been carried out on two carbon steel samples cut off from a heat exchanger of an oil refinery and potentially affected by HIC. It was shown that the AVR technique did not reveal any damage and was not effective in the case of the investigated samples due to a thin damage zone with respect to the total thickness of the samples. The AUBT method enabled us to indicate and classify the presence of the hydrogen-induced damage; however, it is complicated to use in practise due to the need perform measurements exactly at the same position using two transducers of different frequencies. The method is more suitable for the verification of damage at a particular position, rather than for scanning. Both other methods—TFM and TULA—enabled us to identify the presence of HIC in large areas of samples. The obtained results have been verified using a metallographic analysis of the section cut from the side of the sample. The results of metallographic examinations have been compared with indications observed using above mentioned techniques and a good correspondence was obtained. It was demonstrated, that the TFM method can detect cracks with dimensions close to 200 µm, while larger cracks of 2 mm were observed very evidently using a 7.5 MHz phased array. Overall, the results suggested that the TULA method is the most suitable method for the primary detection of hydrogen-induced cracking, while the TFM is recommended for the precise assessment of the extent of the detected cracking.

Ultrasonic testing of thick and thin Inconel 625 alloys manufactured by laser powder bed fusion

Additive manufacturing of alloys enables low-volume production of functional metallic components with complex geometries. Ultrasonic testing can ensure the quality of these components and detect typical defects generated during laser powder bed fusion (LPBF). However, it is difficult to find a single ultrasonic inspection technique that can detect defects in the large variety of geometries generated using LPBF. In this work, phased array ultrasonic testing (PAUT) is suggested to inspect thick LPBF components, while guided waves are explored for thin curved ones. PAUT is used to detect cylindrical lack of fusion defects in thick LPBF rectangular parts. Practical defects are generated by reducing the laser power at prespecified locations in the samples. The defects’ shape and density are verified using optical microscopy and X-ray computed tomography. Partially fused defects down to 0.25 mm in diameter are experimentally detected using a 10 MHz PAUT probe with the total focusing method post-processing. The experimental results are compared to defect images predicted by finite element simulations. For thin components with curved geometry, guided waves are used to detect powder-filled cylindrical defects. The waves are generated using piezoelectric transducers, and the spatiotemporal wavefield is measured using a scanning laser Doppler vibrometer. Using root-mean-square imaging of the wavefield, defects down to 1 mm are clearly detected despite the complex internal features in the samples.

Effects of Thermal Gradients in High-Temperature Ultrasonic Non-Destructive Tests.

Ultrasonic inspection techniques and non-destructive tests are widely applied in evaluating products and equipment in the oil, petrochemical, steel, naval, and energy industries. These methods are well established and efficient for inspection procedures at room temperature. However, errors can be observed in the positioning and sizing of the flaws when such techniques are used during inspection procedures under high working temperatures. In such situations, the temperature gradients generate acoustic anisotropy and consequently distortion of the ultrasonic beams. Failure to consider such distortions in ultrasonic signals can result, in extreme situations, in mistaken decision making by inspectors and professionals responsible for guaranteeing product quality or the integrity of the evaluated equipment. In this scenario, this work presents a mathematical tool capable of mitigating positioning errors through the correction of focal laws. For the development of the tool, ray tracing concepts are used, as well as a model of heat propagation in solids and an experimentally defined linear approximation of dependence between sound speed and temperature. Using the focal law correction tool, the relative firing delays of the active elements are calculated considering the temperature gradients along the sonic path, and the results demonstrate a reduction of more than in the error of flaw positioning.

On the wave propagation in a higher-order multi-phase curved porous system

The porosity affecting the vibrational characteristics of structures should be considered due to the fact that these porosities can happen during the manufacturing process. The solid body and the liquid or gas compose the porous materials. In this regard, for the first time, wave propagation corresponding to the curved panel made of reinforced porous composites is investigated. Higher-order shear deformable theory (HSDT) is employed in order to extract the formulation. The effective material is attained by employing the rule of the mixture as well as the modified Halpin–Tsai model. Also, equations of motions that are solved analytically are extracted via Hamilton’s principle. The impacts of radius-to-total thickness ratio, the weight fraction of carbon nanotubes (CNTs), porosity factor, that different composite patterns, the pattern of porosity, as well as carbon fibers on phase velocity behavior corresponded with a reinforced curved porous panel are studied. The presented results can be employed in ultrasonic inspection techniques as well as structural health monitoring.

Defect Imaging Enhancement through Optimized Shape Factors of the RAPID Algorithm Based on Guided Wave Beam Pattern Analysis.

In this study, a modified imaging algorithm was implemented to improve the imaging accuracy for defects located on a structure. Based on analysis of the Lamb wave mode, a guided ultrasonic wave inspection technique was applied, which was able to illustrate images of defects in a 6 mm steel plate simulating containment liner plate (CLP) in nuclear power plants. The dominant Lamb wave mode was determined through short-time Fourier transform waveform analysis and imaging verification. Following tomography verification, limitations of the antisymmetric mode in the thick steel plate were identified. In addition, a modified shape factor, based on the energy distribution factor according to the beam pattern and beam width, was suggested for field applications and improved imaging accuracy. Results of the analysis revealed a beam skewing phenomenon for the Lamb wave mode. In the case of S0 2.7 MHz·mm, skewing as well as distortion effects are not observed in the experiment, while the S0 modes at 2.64 and 2.74 MHz·mm show either of them. Considering skewing width, the size of the shape function was modified. Application of the modified shape function allows us to obtain more accurate image to actual defect shape.