Ultrasonic Nondestructive Evaluation Research Articles

Quantitative Measurement and Evaluation of High-Resolution Ultrasonic Sound Fields using a Novel Automated Ultrasonic Immersion Scanner

Ultrasonic probes are an integral part of the automated ultrasonic non-destructive testing and evaluation (NDT&E) systems to detect and size the defects in a wide range of structural materials in production lines. A complete quantitative assessment of the performance characteristics of an application-specific UT probe is needed to be evaluated on the basis of the international standard DIN EN ISO 22232-2. This requirement of full assessment not only improves the quality assurance of the manufactured probes by evaluating the acceptance criteria but also provides the useful technical information to the end-user to optimize the automated ultrasonic testing on-site. In addition, the evaluation of probe characteristics should be carried periodically throughout their service life. In this work, we developed a novel high-precision ultrasonic immersion scanner to evaluate the full ultrasonic probe characteristics which include the squint angle measurement in three different reference planes (XY, XZ, and YZ), RF-signal and its frequency spectrum at water-steel interface, focal distance, focal range, focal width, focal length and also the angle of beam divergence in different planes of the sound field distribution. In the newly developed UT immersion scanner, for the first time, we successfully integrated the high-precision Hexapod with six axes to achieve a few micrometer (~15 µm) spatial-resolution in the measured sound field patterns and a good angular resolution (~0.05°) in the squint angle measurement. In addition, we used a verified UT instrument in accordance with the standard DIN EN ISO 22232-1 to obtain more accurate amplitude values (±0.5 dB) while scanning a test block. The automated scanning, data acquisition, evaluation, visualization and the automated test report generation are carried based on the standard DIN EN ISO 22232-2. The measured sound beam characteristics of both focused and non-focused application-specific ultrasonic probes with center frequencies ranging from 0.2 - 15 MHz using the pulse-echo technique on a 3 mm half-ball steel reflector are presented. In addition, the measured sound beams of an application-specific 5 MHz multi-element transmit-receive (TR) probe using the 3 mm flat-bottomed-hole (FBH) reflector in a steel reference plate are discussed. Finally, the quantitative analysis of the measured sound field results and the acceptance criteria in accordance with DIN EN ISO 22232-2 are discussed.

Evaluating Diffusion Models for the Automation of Ultrasonic Nondestructive Evaluation Data Analysis

We develop decision support and automation for the task of ultrasonic non-destructive evaluation data analysis. First, we develop a probabilistic model for the task and then implement the model as a series of neural networks based on Conditional Score-Based Diffusion and Denoising Diffusion Probabilistic Model architectures. We use the neural networks to generate estimates for peak amplitude response time of flight and perform a series of tests probing their behavior, capacity, and characteristics in terms of the probabilistic model. We train the neural networks on a series of datasets constructed from ultrasonic non-destructive evaluation data acquired during an inspection at a nuclear power generation facility. We modulate the partition classifying nominal and anomalous data in the dataset and observe that the probabilistic model predicts trends in neural network model performance, thereby demonstrating a principled basis for explainability. We improve on previous related work as our methods are self-supervised and require no data annotation or pre-processing, and we train on a per-dataset basis, meaning we do not rely on out-of-distribution generalization. The capacity of the probabilistic model to predict trends in neural network performance, as well as the quality of the estimates sampled from the neural networks, support the development of a technical justification for usage of the method in safety-critical contexts such as nuclear applications. The method may provide a basis or template for extension into similar non-destructive evaluation tasks in other industrial contexts.

Ultrasonic Nondestructive Evaluation of Composite Bond Strength: Quantification through Bond Quality Index (BQI)

This article presents a concept, materials, and methods to devise a Bond Quality Index (BQI) for assessing composite bond quality, approximately correlating to the respective bond strength. Interface bonding is the common mechanism to join two composite structural components. Ensuring the health and quality of the bond line between two load-bearing composite structures is crucial. The article presents the classification and data-driven distinction between two types of bond lines between similar structural components. The interface bonds in composite plates were prepared using polyester peel ply and TX-1040 nylon peel ply. For all the plates, ultrasonic inspection through scanning acoustic microscopy (SAM) (>10 MHz) was performed before and after localized failure of the plate by impinging energy. Energy was impinged 0–10 J/cm2 of in the 16-ply plates, and 0–25 J/cm2 were impinged in 40-ply plates. Followed by bond failure and SAM, a new parameter called the Bond Quality Index (BQI) was formulated using ultrasonic scan data and energy data. The BQI was found to be 0.55 and 0.45, respectively, in plates with polyester peel ply and TX-1040 nylon peel ply bonds. Further, in 40-ply plates with polyester peel ply resulted in a BQI equivalent to 3.49 compared to 0.75 in plates with a TX-1040 nylon peel ply bond. Currently, the BQI is not normalized; however, this study could be used for AI-driven normalized BQIs for all types of bonds in the future.

Early detection of steel tube welded joint failure using SPC-I nonlinear ultrasonic technique

Welding is a commonly used method for joining two or more parts together in steel construction. Various defects in weld regions such as cracks, pores, and slag inclusion can be present from the beginning, generated during the welding process, or can be developed while in service. Such defects are the weak spots that degrade the structure’s quality and can lead to structural failures. Therefore, early detection of these defects in welded joints, before visible cracks appear, is very important. Using appropriate ultrasonic non-destructive testing and evaluation (NDT&E) techniques, one can detect these defects and take remedial actions to prevent catastrophic structural failures. Guided acoustic wave-based techniques have been proven to be effective for damage detection in steel pipes and rods. Several studies have previously attempted to detect damage in steel tubes using guided ultrasonic waves. Unlike earlier attempts which mostly focused on conventional linear ultrasonic techniques, a relatively new nonlinear ultrasonic technique called sideband peak count-index (SPC-I) is carried out in this research. For this investigation, cast steel components and round hollow structural sections are welded together, and a four-point bending test is conducted under fatigue loading. The welded joints are continuously monitored in real time using strain gages and lead zirconate titanate (PZT) transducers. The PZT transducers are used to generate and receive guided acoustic waves. The signal is propagated through the specimen in a single-sided transmission mode setup. The strain gage readings and the nonlinear ultrasonic parameter, the SPC-I values, are monitored simultaneously. The results obtained from the nonlinear ultrasonic NDT&E measurements are compared with the data obtained from the strain gages to determine the robustness and reliability of the SPC-I technique for monitoring welded joints. This investigation also shows the potential effectiveness of the nonlinear ultrasonic parameter SPC-I for early detection of weld failure.

Determination of the anisotropy in mechanical properties of laser powder bed fusion Inconel 718 by ultrasonic testing

ABSTRACT This study aims to investigate the effects of build direction on the as-fabricated microstructure and mechanical properties of Inconel 718 specimens manufactured via the Laser Powder Bed Fusion (L-PBF) technique. The microstructures and mechanical properties of the specimens were characterized via SEM, EBSD,ultrasonic wave velocity measurements, hardness and tensile tests. For the as-fabricated condition, the highest tensile strength (1114 MPa) was obtained with the horizontally built specimens while the vertically built ones have the highest 40% elongation. The computational analysis produced results that closely aligned with the measured yield strength values of L-PBFed samples. Additionally, a strong correlation was observed between the hardness values and longitudinal ultrasound velocity of L-PBF Inconel 718 specimens. Consequently, the non-destructive ultrasonic evaluation provided valuable insights into the anisotropy of mechanical properties, complementing information obtained from conventional tensile tests.

Utilizing the derivative of unwrapped phase in ultrasonic nondestructive evaluation of elastic properties of polymer filaments.

Polymer filaments represent the fundamental materials employed in fused filament fabrication additive manufacturing. This paper uses an innovative nondestructive evaluation technique for gauging the elastic properties of these polymer filaments. The method hinges on acoustic wave scattering theory, wherein a polymer filament is immersed in water and exposed to an incident acoustic wave. The waves scattered from the cylinder contain crucial information concerning the elastic properties of the filament. To extract these properties, an inverse method is applied which compares the resonance frequencies of the scattered signal with those anticipated based on a theoretical model. To improve the performance of this method in identifying the resonance frequencies, the derivative of the unwrapped phase within the backscattered pressure spectrum is analyzed. This is an advantageous approach as it can be equally applied to both experimental and theoretical pressure spectra, simplifying the task of identification of resonance frequencies considerably. The method's effectiveness is exemplified through its application to an aluminum rod followed by its application to two polymer filaments. Comparing the elastic constants of the polymer filaments determined through the proposed method with values reported in the literature underscores the method's capability to accurately measure the elastic constants of polymer filaments.

Ultrasonic evaluation of wire-to-terminal joints: integrating XGBoost machine learning with finite element feature analysis

ABSTRACT A new scheme for ultrasonic non-destructive evaluation of wire-to-terminal joints was developed in this study. A finite element simulation model of 2D porous media based on X-CT images of an NG sample was proposed to analyse acoustic scattering. The simulation signal features were extracted in the time domain, frequency domain, and time-frequency domain, and entropy analysis was conducted to explore the relationship between different characteristic values and porosity, thereby revealing prominent trends in these features. By controlling parameters, 28 welding samples labelled OK and NG were produced, and their echoes were acquired by an ultrasonic Full Matrix Capture (FMC) system. Features of the full matrix signals were extracted, and the combined XGBoost machine learning was used to classify the quality and order the attribution of features. The result highlighted the significance of the waveform factor, margin factor, and kurtosis which are consistent with simulation results. The accuracy of weld quality identification can reach 84%. The three factors may be performance criteria for ultrasonically welded wire-to-terminal joints.

Ultrasonic Features for Evaluation of Adhesive Joints: A Comparative Study of Interface Defects.

Ultrasonic non-destructive evaluation in pulse-echo mode is used for the inspection of single-lap aluminum adhesive joints, which contain interface defects in bonding area. The aim of the research is to increase the probability of defect detection in addition to ensuring that the defect sizes are accurately estimated. To achieve this, this study explores additional ultrasonic features (not only amplitude) that could provide more accurate information about the quality of the structure and the presence of interface defects. In this work, two types of interface defects, namely inclusions and delaminations, were studied based on the extracted ultrasonic features in order to evaluate the expected feasibility of defect detection and the evaluation of its performance. In addition, an analysis of multiple interface reflections, which have been proved to improve detection in our previous works, was applied along with the extraction of various ultrasonic features, since it can increase the probability of defect detection. The ultrasonic features with the best performance for each defect type were identified and a comparative analysis was carried out, showing that it is more challenging to size inclusion-type defects compared to delaminations. The best performance is observed for the features such as peak-to-peak amplitude, ratio coefficients, absolute energy, absolute time of flight, mean value of the amplitude, standard deviation value, and variation coefficient for both types of defects. The maximum relative error of the defect size compared to the real one for these features is 16.9% for inclusions and 3.6% for delaminations, with minimum errors of 11.4% and 2.2%, respectively. In addition, it was determined that analysis of the data from repetitive reflections from the sample interface, namely, the aluminum-adhesive second and third reflections, that these contribute to an increase in the probability of defect detection.

Simulations and experimentation of ultrasonic wave propagation and flaw characterisation for underwater concrete structures

ABSTRACT Ultrasonic non-destructive evaluation of concrete submerged in water is a complex phenomenon that has important implications for the durability and safety of marine structures such as bridges, piers and offshore platforms. The scattering of ultrasonic waves inside concrete materials with aggregate size comparable to the ultrasound wavelength often limits the interpretation of inspection results. To enhance the understanding of ultrasonic wave propagation inside the underwater concrete, numerical simulations using the finite element method (FEM) with the Transient Acoustics-Piezoelectric Interaction application mode of Multiphysics software package have been developed. This study focuses on developing a 2D numerical model to reproduce and illustrate the propagation of ultrasound in seven types of underwater concrete test blocks with various types of inclusions and voids embedded inside it. The B-Scan 2D images of the concrete test blocks were acquired using the simulated data and compared with experimental results acquired using an in-house developed four-channel ultrasonic imaging system. Both simulation and experimental results showed a good resemblance, indicating that B-Scan imaging can be applied to identify and characterise various types of defects and inclusions in underwater concrete structures, providing better assessment of the material than conventional ultrasonic pulse velocity (UPV) method.

A comparison of methods for generating synthetic training data for domain adaption of deep learning models in ultrasonic non-destructive evaluation

This work provides a solution to the challenge of small amounts of training data in Non-Destructive Ultrasonic Testing for composite components. It was demonstrated that direct simulation alone is ineffective at producing training data that was representative of the experimental domain due to poor noise reconstruction. Therefore, four unique synthetic data generation methods were proposed which use semi-analytical simulated data as a foundation. Each method was evaluated for its performance in the classification of real experimental images when trained on a Convolutional Neural Network which underwent hyperparameter optimization using a genetic algorithm. The first method introduced task specific modifications to CycleGAN, a generative network for image-to-image translation, to learn the mapping from physics-based simulations of defect indications to experimental indications in resulting ultrasound images. The second method was based on combining real experimental defect free images with simulated defect responses. The final two methods fully simulated the noise responses at an image and signal level respectively. The purely simulated data produced a mean classification F1 score of 0.394. However, when trained on the new synthetic datasets, a significant improvement in classification performance on experimental data was realized, with mean classification F1 scores of 0.843, 0.688, 0.629, and 0.738 for the respective approaches.

Asymmetric elastic wave scattering in elastic plates

Reciprocity is a fundamental principle that can be used to understand a wide range of wave phenomena. In reciprocal systems, the exchange of source and receiver between two points yields the same displacement at the receiver if the applied force at the source is the same for both configurations. The reciprocity principle enforces restrictions on the scattering matrix in an acoustic or elastic system, but these relationships are not obvious when multiple modes are present, particularly when modes are coupled due to the presence of asymmetric scatterers. In this talk, we apply the reciprocity principle in a simplified two-dimensional waveguide case to prove symmetry of the scattering matrix in passive systems with and without loss and establish requirements for asymmetric scattering. The requirements enforced by reciprocity and energy conservation are then generalized to Lamb modes of arbitrary order. Applications to acoustic and elastic metamaterial design and ultrasonic nondestructive evaluation are discussed. [Sandia National Laboratories is a multimission laboratory managed and operated by National Technology and Engineering Solutions of Sandia, LLC., a wholly owned subsidiary of Honeywell International, Inc., for the U.S. Department of Energy’s National Nuclear Security Administration under contract DE-NA-0003525.]

Ultrasonic Monitoring of Ash Contents and MBTS Accelerator Mixed Nitrile Rubber during the Vulcanization Process

Nitrile-butadiene rubber, commonly known as nitrile rubber, is one of the most usable synthetic rubbers that exhibits excellent heat and oil resistance. Nitrile rubber has a variety of applications, such as manufacturing of gaskets, footwear, sponges, and so on, where natural rubbers cannot be used. This paper presents a unique method of monitoring the vulcanization process in real time for nitrile rubber mixed with varied ash content (china clay and whiting) and an MBTS (benzothiazyldisulfide) accelerator using ultrasonic nondestructive evaluation (NDE). An experimental setup includes a fully automated system for acquiring ultrasonic data that has been developed in-house. It has been found that ultrasonic velocity can distinguish between china clay and whiting content in rubber, along with monitoring the curing rate and completion of curing of rubber. The cross-link density of every test sample is calculated using the equilibrium swelling method, followed by its evaluation using ultrasonic responses.

Ultrasonic testing for metal additive manufacturing: Experience with new course development

Metal additive manufacturing (AM) has brought about the need for nondestructive evaluation (NDE) methods to assess part quality. AM processes result in complex microstructures, porosity, material texture, and residual stresses all of which may vary spatially throughout the part. Thus, knowledge of ultrasonic NDE methods to characterize materials is relevant to the AM community. To address this challenge, a new graduate-level course entitled “Ultrasound for Metal Additive Manufacturing,” was created at the University of Nebraska-Lincoln. The course followed a cognitive-situative blended learning approach to give students practical ultrasonics training regardless of prior acoustics background. The theory introduced key topics including: the general wave equation, plane wave solutions, waves in isotropic solids, impact of material anisotropy, role of material interfaces, reflection and transmission, surface waves, scattering, dispersion, material dissipation, and scattering attenuation. A series of laboratory experiments allowed students to learn: experimental setups, signal processing, transducer properties and selection, beam mapping, wave speed and attenuation measurements, and diffuse-field measurements. Finally, each student developed a project incorporating ultrasound measurements into their individual AM research. Their findings were included in research articles, conference presentations, and PhD dissertations. This presentation will describe the course design, successes, and recommendations for future implementations.

Microstructure quality assessment for hybrid additive manufactured Ti6Al4V components via ultrasonics

Metal components with functionally organized microstructures for specific applications are emerging thanks to hybrid additive manufacturing (AM). The customization of these high value components accentuates the need for nondestructive methods to characterize their microstructural functional patterns. Nondestructive evaluation (NDE) methods that are economical, fast, energy efficient, and easy to integrate into routine component inspections are preferred. Most importantly, NDE methods must be sensitive to changes in the microstructure such that regions that do not satisfy the design requirements (i.e. out-of-spec regions) can be detected. In this work, ultrasonic NDE methods grounded in diffuse backscatter modeling were used to detect and quantify spatial property variations resulting from a hybrid AM process. The manufacturing process coupled directed energy deposition (DED) with milling in a cyclical manner. These methods were successfully implemented to evaluate the microstructural uniformity of Ti6Al4V samples as well as to make comparisons across an ensemble of samples manufactured with identical parameters. Out-of-spec regions were mapped with respect to the sample geometry on a layer-by-layer basis. The results of this work are expected to inform future NDE strategies for both research and practitioner contexts, and limitations are discussed.

Imaging elastic waves in solids: how to use laser feedback interferometry to visualize them.

The use of ultrasonic elastic waves is a well established technique for non-destructive testing of materials and structures, in particular to exploit the interaction of waves with structural features to detect and characterize defects. Optical methods offer the advantage of visualising the distribution of elastic waves in a non-contact manner without disturbing the elastic wave. In this work we propose a laser feedback interferometry (LFI) based system as a cost effective, non-contact, alternative to a well established laser Doppler vibrometer technique. We demonstrate the visualization of the elastic waves, using an example of an elastic wave propagating through a prismatic acrylic rod. We show that the ultra-compact and simple implementation of LFI enables accurate visualization of the elastic waves in solids, and opens the pathway to a range of new opportunities in ultrasonic non-destructive testing and evaluation.

Approaches to Ultrasonic Non destructive Evaluation of Composites in Aircraft Components

Non-Destructive Evaluation (NDE) has played a pivotal role in the course of development of composites in airframe structural components at the Advanced Composites Division (ACD) of National Aerospace Laboratories (NAL), through novel co-curing, co-bonding fabrication routes. An account of Ultrasonic NDE through C-scan technique on advanced composites is given here.

Ultrasonic evaluation of ply and interleaf layer properties of interleaved composite laminates

An ultrasonic nondestructive evaluation procedure is presented for the ply and interleaf layer properties of carbon/epoxy composite laminates having interleaf resin layers at their interlaminar interfaces. It is shown that the material properties of plies (density, thickness, and transversely isotropic complex elastic moduli) and elastic interleaf layers (density, thickness, Young’s modulus, and Poisson’s ratio) can be identified by best fitting the theoretical energy transmission spectra of longitudinal waves through the laminate immersed in water to those obtained in ultrasonic measurement. It is also demonstrated that compared to the mass-less and null-thickness spring-type interlaminar interface model employed in the previous works, the present finite-thickness interleaf layer model can better reproduce the experimental transmission spectra of a unidirectional interleaved composite laminate containing ultrasonic bandgaps. Furthermore, the property characterization in the case where the plies and interleaf layers are assumed to be elastic and viscoelastic, respectively, is also examined. It is also shown that the ply and interleaf layer properties determined for the unidirectional laminate can be used to reproduce the transmission spectra measured for a quasi-isotropic laminate consisting of the same plies and interleaf layers.

Critical Examination of Distance-Gain-Size (DGS) Diagrams of Ultrasonic NDE with Sound Field Calculations.

Ultrasonic non-destructive evaluation, which has been used widely, can detect and size critical flaws in structures. Advances in sound field calculations can further improve its effectiveness. Two calculation methods were used to characterize the relevant sound fields of an ultrasonic transducer and the results were applied to construct and evaluate Distance-Gain-Size (DGS) diagrams, which are useful in flaw sizing. Two published DGS diagrams were found to be deficient because the backward diffraction path was overly simplified and the third one included an arbitrary procedure. Newly constructed DGS diagrams exhibited transducer size dependence, revealing another deficiency in the existing DGS diagrams. However, the extent of the present calculations must be expanded to provide a catalog of DGS diagrams to cover a wide range of practical needs. Details of the new construction method are presented, incorporating two-way diffraction procedures.

Characterizing the As-Fabricated State of Additively Fabricated IN718 Using Ultrasonic Nondestructive Evaluation

This article reports on the characterization of the “as-fabricated” state of Inconel 718 samples fabricated using laser directed energy deposition (DED). Laser-DED is known to produce complex metastable microstructures that can significantly influence the baseline ultrasonic response compared to conventional processing methods. The present work uses three parameters to characterize the samples: (a) ultrasonic velocity, (b) an attenuation coefficient, and (c) a backscatter coefficient. The baseline ultrasonic response from the DED sample was compared against the ultrasonic properties of conventional IN718 samples reported in the literature. The results suggest that strong grain boundary scattering from large macrograins can lead to attenuation and backscatter values that are significantly higher than conventional samples. Additionally, the results including velocities, attenuation and backscatter coefficients were found to be dependent on the fabrication direction, with the build direction being different from the transverse directions. Finally, destructive analysis was used to develop conjectures to explain the experimentally observed ultrasonic response.

Reliability and failure modelling of microelectronic packages based on ultrasonic nondestructive evaluation data

Reliability testing and failure modelling is crucial and very challenging for modern electronics, especially safety critical electronics-based systems working under harsh environmental conditions. In this paper, an approach based on ultrasonic Non-Destructive Evaluation (NDE) is proposed to establish a failure model for solder joints which is urgently needed for prognostic and health management of electronics. Printed Circuit Boards (PCB) containing flip-chip and Area Array packages were designed and aged using Accelerated Thermal Cycling (ATC) testing. During ATC testing solder joint degradation was regularly monitored by taking out the test boards from the temperature chamber at four thermal cycle intervals for ultrasonic micro-imaging. Data pre-processing techniques including dynamic range-based intensity normalization, gain compensation, and calibration for random transducer defocusing errors were developed to enhance the data consistency, integrity and accuracy. Furthermore, solder joint image labelling and segmentation methods were developed by exploiting the geometrical features of the solder joints to extract individual solder joints and Region of Interests (ROIs) from the sequential ultrasound images collected throughout the testing. The mean intensity of the ROIs was used as the precursor to degradation to build the solder joint failure model, from which cycles to failure for individual solder joints are finally derived for life prediction.