Ultrasonic Testing Research Articles

Simulation study of turning-ultrasonic rolling compound processing for 42CrMo steel

The ultrasonic rolling processing technology has been shown to significantly reduce surface roughness and enhance the residual stress of parts, thereby improving their surface properties and extending their service life. This technology is particularly effective for the precision machining and surface strengthening of ultra-high-strength steel 42CrMo. This study aims to investigate the impact of turning pre-processing on the distribution of residual stress during ultrasonic rolling, a simulation model incorporating turning pre-processing was developed and used to conduct ultrasonic rolling simulation experiments, enabling the analysis of residual stress distribution patterns. Concurrently, ultrasonic rolling strengthening experiments were performed to validate the accuracy of the simulation model. The results confirm that with increasing rotational speed and feed rate, residual stress decreases, whereas with increasing static pressure and amplitude, residual stress increases. The residual stress variation obtained from the simulation of combined turning and ultrasonic rolling closely matched the results of experimental ultrasonic rolling tests. This consistency validates the accuracy of the simulation model. This study offers a novel approach for simulating and experimentally validating ultrasonic rolling processes, particularly for shaft-like parts that undergo turning as a pre-processing step.

Application Study of Acoustic Reflectivity Based on Phased Array Ultrasonics in Evaluating Lubricating Oil Film Thickness

Bearings play a key role in rolling mills, and the uniformity of their lubricant film directly affects the degree of wear of bearings and the safety of equipment. Due to long-term stress, the lubricant film inside the bearing is not uniformly distributed, resulting in uneven wear between the journal and the shaft tile, which increases the potential safety hazards in production. Traditional disassembly inspection methods are complex and time-consuming. Ultrasonic nondestructive testing technology, which has the advantages of nondestructive and adaptable, has become an effective means of assessing the thickness of the oil film in bearings. In this study, an experimental platform for calibrating the lubricant film thickness in bearings was constructed for the first time, and the acoustic characteristics of different thicknesses of the oil film were measured using ultrasonic detection equipment to verify the accuracy of the simulation process. The experimental results show that after discrete Fourier transform processing, the main features of the frequency channels of the reflected acoustic signals of different thicknesses of the oil film are consistent with the finite element simulation results, and the errors of the oil film thicknesses calculated from the reflection coefficients are within 10% of the set thicknesses, and the measurement ranges cover from 5 μm to 250 μm. Therefore, the above method can realize the accurate measurement of the thicknesses of the oil film in bearings.

Image restoration of reflectors by the method of digital aperture focusing in thick-walled pipes of small diameter

In ultrasonic inspection of pipes of various diameters using antenna arrays and arrays, two technologies of reflector image reconstruction are widely used: antenna array focusing technology (PAUT) and digital aperture focusing (DAF) technology. If the tube diameter is larger than a hundred wavelengths, the DAF method can be used to reconstruct the reflector image by taking into account several reflections from the boundaries, assuming that the object of inspection is flat. In this case, the errors in the formation of DAF-image of reflectors will be insignificant. However, if the pipe diameter is several tens of wavelengths and the wall thickness is about half of the pipe diameter, then in this case the geometry of the inspection object must be taken into account to obtain a high-quality DAF-image of the reflectors. The paper considers the peculiarities of image formation at registration of echo signals by an antenna array or matrix, when scanning both on the external and internal surfaces of the object of control. In numerical and modeling experiments it is shown that both antenna array and antenna array can be used to obtain high-quality DAF-image of reflectors when scanning along the outer surface of a thick-walled pipe of small diameter. This is due to the presence of the effect of physical focusing of the ultrasonic field. But when scanning along the inner surface of a thick-walled tube of small diameter, because of the defocusing effect, it is necessary to register echoes with an antenna array to restore the image of reflectors.

Multi-mode high resolution TFM imaging of microdefects based on laser ultrasonic full matrix capture

The identification and visualization of submillimeter microdefects have long been a critical focus within the realm of ultrasonic testing. The utilization of high-frequency signals is imperative due to the small acoustic interaction structure. An additional benefit of using lasers is their non-contact nature and ability to utilize multiple imaging modes, effectively reducing false or missed detections and enhancing credibility. This study proposes an advanced optimization algorithm for imaging and quantitative evaluation of submillimeter microdefects using laser ultrasonic full matrix capture (FMC) and total focusing method (TFM). The analysis of acoustic directionality under laser excitation and detection provides a foundation for mode selection. In preprocessing, the multi-scale principal component analysis (MSPCA) method is introduced to suppress coherent noise and blind spots. Moreover, phase coherence methods are implemented to further reduce mode artifacts, background noise, and residual surface acoustic wave (SAW). Additionally, multi-mode imaging and mode fusion are achieved using reflected longitudinal waves, reflected shear waves, converted longitudinal waves, and converted shear waves. Experiments were carried out on two different types of microdefects, namely side drilled holes (SDHs) and blind holes (BHs), resulting in high resolution TFM imaging with a minimum BH size of 0.3 mm. The outcomes demonstrate the efficacy of MSPCA in suppressing coherent noise, with further enhancement in imaging quality after phase coherence weighting. In addition, the −6 dB threshold of multi-mode images also provided the size information. This research is poised to contribute to the resolution of quality assessment challenges in powder metallurgy, welding, and additive manufacturing processes.

Theory of similarity and ultrasonic testing

Application of similarity theory (dimensional analysis) to ultrasonic (UT) testing is discussed using as an illustration the example of concrete blocks. The concept of dimensional analysis makes it possible to represent a physical system via a minimal set of variables, the so-called π groups, which are the dimensionless quantities. These dimensionless parameters, characterizing the respective phenomenon, should have approximately equal values for the real object and for the model. Small concrete samples have been tested in the lab conditions using various UT probes and techniques. Two dimensionless criteria, valid and similar for the real field case and for the laboratory samples, have been introduced: total attenuations of UT waves and ratios of void size to the UT wavelength. To get total attenuations in the field conditions for thick concrete block, similar to the total attenuations measured in lab experiments on small samples, one should apply the low-frequency UT waves 60-100kHz. However, these UT waves will be able to reliably detect only the large inhomogeneities (e.g. voids), whose size is about half of the used UT wave, i.e. inhomogeneities with dimensions larger than 20-40mm.

Translation of MFL and UT data by using generative adversarial networks: A comparative study

Magnetic flux leakage (MFL) and ultrasonic testing (UT) are widely used in-line inspection technologies to detect corrosion defects along pipelines. The integration of MFL and UT data has the potential to provide complementary insights that facilitate a comprehensive assessment of pipeline integrity. However, due to the inherent dissimilarity with their underlying physical principles, these techniques yield notable disparities in signal characteristics, posing challenges in integrating these multimodal data. This study aims to establish a translation mapping between MFL and UT signals to achieve consistent physical interpretations across the two modalities. Thus, this study explored the feasibility of generative adversarial network (GAN) based models encompassing both supervised and unsupervised translation approaches contingent on the availability of aligned data. Furthermore, two translation modes, MFL-UT and UT-MFL, were analyzed, respectively, to understand the effectiveness of the translation direction. The experimental results demonstrate satisfactory performance for both aligned and unaligned data translation, with the UT-MFL translation direction yielding superior results. Overall, the translation approaches pave the way for future applications, especially in subsequent data analysis tasks such as registration, comparison, and fusion of multimodal data.

Developing flaw sizing methodology in Total Focusing Method (TFM) by EDM calibration blocks

The Total Focusing Method (TFM) represents a significant advancement in ultrasonic inspection, delivering high-resolution imaging by leveraging phased array technology combined with sophisticated data processing algorithms. This synergy enables detailed visualization of flaws in various materials, thereby improving flaw detection and characterization. Despite TFM's capabilities, the lack of a standardized methodology for flaw sizing limits its potential for flaw evaluation. This paper seeks to establish a new paradigm in flaw sizing by introducing a custom methodology specifically designed for TFM, using electrical discharge machined (EDM) calibration blocks that reflect a range of flaw shapes. The research highlights the limitations of conventional side-drilled holes (SDH) for capturing realistic flaw nuances and emphasizes the superior ability of EDM notches to simulate the complex geometries inherent in typical flaws. By investigating the influence of different TFM modes, the study provides insight into their effectiveness in improving the accuracy of flaw characterization. Our approach addresses the challenges of existing TFM practices, with EDM notches serving as an essential tool in methodological advancement. This work contributes to the continued development of best practices in TFM application, paving the way for more accurate, reliable, and versatile nondestructive testing.

Synthetic aperture probe and ultrasonic testing

Application of synthetic aperture probes to ultrasonic testing is discussed using as an illustration the dry-contact between two metal surfaces. Synthetic aperture concept uses the motion of the realistic probe over a target region to provide finer spatial resolution than conventional realistic transducer. Typically, the larger the aperture, the higher the image resolution is. We compared results, obtained applying synthetic aperture procedure to standard spherically focused probe with goal to synthesize the large aperture, and results, obtained using novel cylindrically focused transducer with real large aperture. Obtained experimental results confirmed efficiency of synthetic aperture concept in time domain and frequency domain.

Acoustic emission for monitoring of fatigue damage in concrete elements of wind turbine towers

Wind energy has become an important player in the energy transition in Germany. Towers of onshore wind turbines are often designed as hybrid structures: the lower part is made of prestressed concrete whereas the upper part is made of steel tubes. The tall structures are permanently subjected to dynamic loads. A research project of BAM as part of the joint project WinConFat-Structure focusses on the development of techniques to monitor fatigue damage evolution in the concrete part. Results of a previous project show that a combination of ultrasonic and acoustic emission testing can give an indication for critical conditions near the end of the fatigue life of the concrete. In the ongoing project acoustic emission sensors have been installed at the base and at the transition piece between concrete and steel of a hybrid wind turbine tower. Beside of acoustic emission measurement the sensor spacing allows for measuring the concrete ultrasonic velocity along the circumference in both levels. Additional measurements like strain, temperature, inclination, or acceleration allow for comparison of environmental loads and change of acoustic properties of the concrete. The paper focusses on first acoustic measurements recorded since December 2023 in comparison to operating data of the wind turbine.

Analysis and numerical simulation of different flowmeters based on an open channel in an irrigation area

ABSTRACT This study establishes an ultrasonic open channel flow measurement test and numerical simulation model and systematically compares the performance and reliability of the ultrasonic method and the traditional flowmeter in flow measurement in the irrigation area by observing and analysing the test data and combining it with the numerical simulation. In the indoor ultrasonic flowmeter flow measurement experiments in the trapezoidal nullah section, the flow rate measurement was carried out by using a high-precision variable slope flume and a variety of flow measurement tools. A numerical study was carried out using the VOF method to calculate the flow in the open channel flume under two-phase flow conditions. Combining experimental measurements and numerical simulations, this study aims to quantify the magnitude of flow measurement errors and water surface fluctuations in open channel flumes and to address the discrepancies between different flow measurement methods in open channels in irrigation areas.

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.

DISPERSION OF LAMB WAVES IN MULTILAYER STRUCTURES

Low cost, the possibility of online monitoring and high sensitivity distinguish the method of structural monitoring using Lamb waves from other available methods. Structural analysis based on Lamb waves in heterogeneous materials requires fundamental knowledge of the behavior of Lamb waves in such materials. This basic knowledge is critical for signal processing in determining possible damage that can be detected by the propagating wave. Recently, Lamb wave methods have been used to simultaneously survey large areas of composite structures. However, such methods are more complex than traditional ultrasonic testing because Lamb waves have dispersive characteristics, namely, the wave speed varies depending on the frequency, modes and thickness of the plates. Experimentally measured group velocities of Lamb waves in composite materials with anisotropic characteristics do not coincide with theoretical group velocities, which are calculated using the dispersion equation of Lamb waves. This discrepancy arises because in anisotropic materials there is an angle between the direction of the group velocity and the direction of the phase velocity. This work investigates the propagation characteristics of Lamb waves in composites, focusing on group velocity and characteristic wave curves. For symmetric laminates, a robust method is proposed by imposing boundary conditions on the mid-plane and top surface to separate symmetric and antisymmetric wave modes. The dispersive and anisotropic behavior of Lamb waves in two different types of symmetrical laminates is theoretically studied in detail. The dispersion of Lamb waves was studied for 10 symmetric and asymmetric modes. It is shown that only fundamental modes are not characterized by a cutoff frequency, which indicates the interaction of fundamental modes with composite layers in the low-frequency range. A high level of group velocity dispersion was discovered for the SH0 and S0 modes. It is concluded that in isotropic laminates, dispersion is characteristic of symmetric modes. It is shown that the frequency dependence of the group velocity of Lamb waves of laminar composites can be represented in polynomial form.

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.

تحديد العمر المتبقي لأوعية الضغط الأسطوانية باستخدام تقنية الفحص بالموجات فوق الصوتية: دراسة حالة

Pressurized pressure vessels utilized in the upstream sector of the oil and gas industry commonly experience in-service deterioration caused by factors such as corrosion and process-related issues. Most current research has emphasized the significance of calculating remaining lifetime (RLT) but with a little concentration on the Ultrasonic test (UT) for remaining life assessment. In this work, a case study of the pressure vessel unit (20-v-200) belonging to Basra Oil Company (BOC) at Hammar Mishrif Degassing Station (HM-DGS) is conducted. A nondestructive test (NDT) by UT technique was employed over the suspected area of the pressure vessel. Where it was identified the condition monitoring locations (CMLs) around the shell and heads of the pressure vessel, were marked twenty-one locations to obtain their wall thickness measurement. The results of the remaining lifetime showed that for shell and head were computed as 52.9 years and 56.8 years, respectively. Therefore, based on the present result, it can be deduced that the pressure vessel can remain in operation or continue to be in service for the next 52.9 years under the same process conditions. This assessment considers the existing condition of the vessel and indicates that it can meet the required safety and operational standards for an extended duration. However, as an experienced entrepreneur, I would advise that thickness measurement inspections should be conducted within a timeframe that does not exceed either half of the remaining life of the vessel or a maximum of 10 years, according to API 510. This recommendation ensures that regular assessments are performed to monitor the thickness and condition of the vessel. By adhering to this practice, timely maintenance and necessary repairs can be identified and carried out, contributing to the continued integrity and safety of the vessel throughout its operational lifespan.

Ultrasonic TFM imaging inspection of large complex rings using defect quantitative evaluation mappings

ABSTRACT Large complex rings are widely used in wind power energy, aerospace, large construction machinery. There are different scales of defects in the manufacturing process for large complex rings. Because of the complex cross-section and large thickness, it is difficult to quantitative evaluation of defects by conventional ultrasonic technology. Therefore, the ultrasonic total focusing method (TFM) defect quantitative inspection for large complex rings is proposed in this paper. First, the TFM inspection technology of large complex rings for simultaneous scanning of the end-face and side-face is designed. Then, the maximum amplitudes of defects are collected at each grid point of the imaging area by the TFM inspection of calibration specimens. The Φ1.5mm defect quantitative evaluation mappings are obtained by the interpolation fitting algorithm. Finally, the ultrasonic TFM and B-scan inspection experiments of the Φ3440mm large ring are carried out. The results show that the TFM quantitative evaluation mapping has higher accuracy compared to the conventional B-scan method. Especially for the Φ1.5mm defects, the average error of TFM quantitative evaluation is 2.92%. The proposed method can effectively identify defects of other sizes that exceed the calibration mapping. This work has industrial application value for developing ultrasonic TFM inspection of large complex components.

Feasibility of ultrasonic non-destructive testing of ancient funerary urns: Experimental and analytical parametric model

Non-invasive modalities are being developed as the computer tools and industrial non-destructive testing capabilities become more widespread. Using the same investigation methods as those applied to modern objects, we seek to study ancient funerary urns containing human bones. The exploration of ancient urns is key to increasing our understanding of the practices of burial and cremation in archaeo-anthropology. But those urns present at archaeological sites are exposed to diversified environments (wet, temperate or dry environment), and can be subjected to chemical or mechanical destructive actions over time. As ancient funeral urns containers are sometimes made of lead, stone or ceramic, the use of X-ray scanners is difficult or even impossible for in situ control. In this work, we propose an engineering technique based on ultrasonic non-destructive testing and wave propagation in urns. An analytical parametric model is developed using mathematical signal processing tools and validated by means of laboratory experiments under controlled conditions of propagation through reproductions of ancient urns for two ultrasonic frequencies (500 kHz and 1 MHz). The aim is to characterise an ancient urn by creating an analytical model, and to use a parametric identification algorithm to determine the presence or absence of bone fragments. The parametric identification algorithm based on the Levenberg–Marquardt method makes it possible to determine the geometrical (thickness) and physical (wave velocity and attenuation, mass density) parameters when the urn is filled with water, with water and bones, and with water, bones and sand. We show that the model makes it readily (processing time ≈15 sec) possible to find the different times of flight between the transducer and the different walls of the urn and the parameters with an accuracy less than 10%.

Evaluation of calcium carbonate production and cementitious characteristics of enzymatically induced carbonate precipitation during environmental adjustment

Enzymatically induced carbonate precipitation (EICP) is an emerging and eco-friendly technology, which is considered a green alternative to traditional cement in soil stabilization. When stabilizing soil use one-phase grouting method, the activity of urease is often adjusted, leads to changes in the composition and cementitious characteristics of CaCO3. Previous studies primarily focused on the mechanical properties of solidified soil samples, while the production and cementitious characteristics of CaCO3 influenced by the control of urease activity is rarely discussed. This study investigated production and cementitious characteristics of CaCO3 under different reaction environment (pH adjustment, temperature adjustment, and addition of inhibitors), during which the urease activity tests, pH tests, CaCO3 production tests and ultrasonic oscillation tests are conducted. Meanwhile, the morphological characteristics and mineral composition of CaCO3 are revealed through Scanning Electron Microscope-Energy Dispersive Spectrometer (SEM-EDS) tests and X-ray Diffraction (XRD) test. The results demonstrate that all three one-phase grouting methods can delay the production of CaCO3 at early-stage of EICP, while the pH should be maintained above 4 to prevent significant urease deactivation. The CaCO3 generated in EICP mainly consists of calcite and vaterite, and the size of CaCO3 increases with the urease activity increased. The cementitious characteristics of CaCO3 is mainly determined by the percentage composition of calcite and vaterite, where higher vaterite content results in weaker cementitious characteristics. This study provides insights for evaluating the cementitious characteristics of CaCO3, which is beneficial for guiding the promotion and application of one-phase grouting method.