Ultrasonic Polar Scan Research Articles

Wave velocity measurement in the through-thickness direction of the anisotropic material plate with ultrasonic polar scan

Ultrasonic polar scan (UPS) records the amplitude in transmission for a wide range of incidence angles, providing a UPS image with characteristic contours reflecting the acoustic parameters of the material. This study focused on a newly developed wave velocity measurement of the DD6 single-crystal material plate by analyzing the UPS image to realize the ultrasonic thickness measurement of the DD6 single-crystal material plate accordingly. Firstly, considering transducer contour size compensation, the UPS images are obtained by numerical simulation on the DD6 single-crystal material plates with different crystal orientations. Secondly, the fitting equations are obtained by analyzing the UPS images to calculate wave velocity in the thickness direction. Finally, a 5-joint UPS scanner is designed to validate the accuracy of wave velocity simulation results experimentally, and it indicates a good agreement with conventional ultrasonic velocity measurement. The measurement results demonstrated that the UPS method could evaluate the wave velocity in the through-thickness direction of the DD6 single-crystal material plate with high precision.

Optimal Design Parameters for a Phased-Array-Based Ultrasonic Polar Scan.

In the context of designing a next-generation ultrasonic polar scan (UPS) measurement system for viscoelastic material characterization, a novel approach is proposed, which draws on a set of cylindrically focused emitters in conjunction with a circular phased array (C-PA) receiver in order to create a portable measurement system while improving the data quality and ease the data interpretation. To explore the potential of the new approach and determine its optimal design parameters, a 3-D analytical model is presented to numerically simulate UPS experiments with the proposed system. Furthermore, a postprocessing procedure is worked out to treat the acquired raw data with the aim to deal with the integrating effect of finite size transducers and directly reconstruct the angle-dependent plane wave reflection coefficients of the sample under study. As the accuracy of the reconstruction heavily depends on various design parameters, a parameter study focusing on the influence of three main experimental parameters is performed to guide the optimal design. For each of these parameter studies, the UPS simulation results have been inverted, and the errors on the estimated C-tensor parameters have been deduced. First, it is shown that, for a given frequency, the radius of the C-PA must be large enough to capture both the specular and nonspecular reflected field, which is crucial to assure a correct reconstruction of the plane wave characteristics and find proper estimates of the C-tensor parameters. Second, the impact of the emitter and receiver lengths on the quality of the reconstruction and the C-tensor parameters has been investigated, yielding superior results upon increasing either of them. Finally, a dedicated study of the pitch of the C-PA elements and the angular range of the cylindrically focused emitters shows that aliasing effects disturb the results if the pitch is too large. However, this effect can somewhat be mitigated by employing multiple emitters with a restricted angular range. Using the knowledge of the abovementioned parameter studies, a simulated UPS experiment using a proper set of design parameters is performed for a cross-ply carbon epoxy laminate. The postprocessed reconstruction based on these data shows an excellent agreement with the theoretical plane wave results.

Characterization of the orthotropic viscoelastic tensor of composites using the Ultrasonic Polar Scan

An enhanced two-stage inversion scheme for the determination of the viscoelastic properties of orthotropic plates (e.g. fiber reinforced polymers) based on the pulsed ultrasonic polar scan (P-UPS) is presented. A forward numerical model for the P-UPS is combined with an efficient optimizer routine (particle swarm optimizer, PSO) to inversely extract the complex orthotropic stiffness tensor, as well as the orientation of the main axes of orthotropy. The developed inversion technique is validated on synthetic data, yielding accurate results with small deviations: elasticity tensor <0.5%, viscosity tensor <2% and main axes of orthotropy <0.03°. The inversion procedure has been further applied to analyze actual experimental P-UPS recordings on an aluminum plate as well as a unidirectional [0]8 carbon/epoxy laminate. The obtained inversion results yield complex stiffness parameters which are in close agreement to reported values in literature, and confirms the potential of the UPS technique and its inversion optimization routine as an enhanced NDT technique to quickly and accurately obtain characteristic material properties of composites.

Numerical Study of a Phased Array-Based Ultrasonic Polar Scan to Determine Plane-Wave Reflection Coefficients of Plates.

Numerical finite-element (FE) simulations and postprocessing analysis methods are presented for ultrasonic polar scan (UPS) measurements involving a circular phased array (C-PA) to determine the plane-wave reflection coefficient of plates. Apodization weights for the C-PA elements are determined to assure the generation of a quasi-plane wave upon excitation at the plate surface and to mitigate bounded beam effects on the assessed reflection coefficient. In addition, postprocessing of the reflection signals is performed via the synthetic plane-wave technique to further filter out any bounded beam effects. Reflection coefficients are presented for three cases namely, an aluminum, a unidirectional carbon epoxy, and a cross-ply carbon epoxy plate. For all three cases, comparison with the analytical plane-wave theory shows excellent agreement with the reflection coefficients obtained by the C-PA and the additional postprocessing steps for both the pulsed and harmonic signals. It is also shown that the agreement becomes considerably worse if the nonspecular reflection field is disregarded in the postprocessing treatment, thus enforcing the need to capture the full reflected field via the PA whenever plane-wave reflection coefficients are needed.

Numerical study of the Time-of-Flight Pulsed Ultrasonic Polar Scan for the determination of the full elasticity tensor of orthotropic plates

A novel approach is presented for the ultrasonic determination of the elastic constants in plate-like structures of an orthotropic material (e.g. composites) using a Time-of-Flight version of the Pulsed Ultrasonic Polar Scan (TOF P-UPS). A forward numerical model of the TOF P-UPS is coupled to an inversion algorithm, based on the genetic optimization principle, targeting the determination of the orthotropic elastic parameters, and the quality of the inversion is demonstrated for synthetic data representative for composites. The advantage of the new approach is that the presented TOF P-UPS inversion method does not require a priori knowledge about the symmetry class of the material, nor about the orientation of the main axes of symmetry. Furthermore, the TOF P-UPS inversion method yields an accurate characterization of the orthotropic elasticity tensor, even when applied to composite plates with small frequency-thickness ratios in which the traditional bulk wave approaches no longer hold. Finally, the robustness of the TOF P-UPS inversion method is demonstrated for noisy data by evaluating the results for a range of signal-to-noise ratios.

The Ultrasonic Polar Scan for Composite Characterization and Damage Assessment: Past, Present and Future

In the early 1980’s, the ultrasonic polar scan (UPS) technique was developed to assess the fiber direction of composites in a nondestructive way. In spite of the recognition by several researchers as being a sophisticated and promising methodology for nondestructive testing (NDT) and materials science, little advance was made during the following 30 years. Recently however, the UPS technique experienced a strong revival and various modifications to the original UPS setup have been successfully implemented. This revival has exposed several powerful capabilities and interesting applications of the UPS technique for material characterization and damage assessment. This paper gives a short historical overview of the UPS technique for characterizing and inspecting (damaged) fiber-reinforced plastics. In addition, a few future research lines are given, which will further expand the applicability and potential of the UPS method to a broader range of (damaged) materials, bringing the UPS technique to the next level of maturity.

Characterization of visco-elastic material parameters by means of the ultrasonic polar scan method

The Ultrasonic Polar Scan (UPS) is a non-destructive technique which insonifies a material spot on a sample using ultrasonic pulses from as many oblique incidence angles ψ(φ,θ) as possible. Mapping the transmitted time-of-flight (TOF) and/or amplitudes as function of the incidence angle ψ(φ,θ) in a polar representation yields a UPS image with intriguing patterns that represent a fingerprint of the local visco-elastic properties. The present paper reports on recent advances in the revival of the UPS technique, involving the construction of an automated high-precision UPS scanner, the implementation of advanced simulation models as well as the development of efficient inversion routines. On the experimental level, unprecedented high quality TOF and amplitude UPS landscapes for a range of orthotropic (fiber reinforced) materials have been obtained. Using numerical simulation models, it can be readily demonstrated that the TOF UPS landscapes are directly connected to the elastic properties of the material, while the signal magnitudes displayed in the amplitude UPS landscapes are merely determined by the viscosity. By developing a coupled inversion scheme using the two landscapes simultaneously, we can achieve a full determination of the visco-elastic tensor. The new advances and inversion scheme will be illustrated in the case of fiber-reinforced plastics.

The quasi-harmonic ultrasonic polar scan for material characterization: Experiment and numerical modeling

Conventionally, the ultrasonic polar scan (UPS) records the amplitude or time-of-flight in transmission using short ultrasonic pulses for a wide range of incidence angles, resulting in a fingerprint of the critical bulk wave angles of the material at the insonified spot. Here, we investigate the use of quasi-harmonic ultrasound (bursts) in a polar scan experiment, both experimentally and numerically. It is shown that the nature of the fingerprint drastically changes, and reveals the positions of the leaky Lamb angles. To compare with experiments, both plane wave and bounded beam simulations have been performed based on the recursive stiffness matrix method. Whereas the plane wave computations yield a pure Lamb wave angle fingerprint, this is no longer valid for the more realistic case of a bounded beam. The experimental recordings are fully supported by the bounded beam simulations.To complement the traditional amplitude measurement, experimental and numerical investigations have been performed to record, predict and analyze the phase of the transmitted ultrasonic beam. This results in the conceptual introduction of the ‘phase polar scan’, exposing even more intriguing and detailed patterns. In fact, the combination of the amplitude and the phase polar scan provides the complete knowledge about the complex transmission coefficient for every possible angle of incidence. This comprehensive information will be very valuable for inverse modeling of the local elasticity tensor based on a single UPS experiment.Finally, the UPS method has been applied for the detection of an artificial delamination. Compared to the pulsed UPS, the quasi-harmonic UPS (both the amplitude and phase recording) shows a superior sensitivity to the presence of a delamination.

Damage Signature of Fatigued Fabric Reinforced Plastics in the Pulsed Ultrasonic Polar Scan

This study investigates the use of both the amplitude and time-of-flight based pulsed ultrasonic polar scan (P-UPS) for the nondestructive detection and evaluation of fatigue damage in fabric reinforced composites. Several thermoplastic carbon fabric reinforced PPS specimens (CETEX), loaded under various fatigue conditions, have been scanned at multiple material spots according to the P-UPS technique in order to extract material degradation in a quantitative way. The P-UPS results indicate that shear dominated fatigued carbon/PPS goes with a reduction of shear properties combined with large fiber distortions. The P-UPS results of the tension-tension fatigued carbon/PPS samples on the other hand reveal a directional degradation of the stiffness properties, reaching a maximum reduction of −12.8 % along the loading direction. The P-UPS extracted damage characteristics are fully supported by simulations, conventional destructive tests as well as visual inspection. The results demonstrate the excellent capability of the P-UPS method for nondestructively assessing and quantifying both shear-dominated and tension-tension fatigue damage in fabric reinforced plastics.

Detection and Localization of Delaminations in Thin Carbon Fiber Reinforced Composites with the Ultrasonic Polar Scan

In this paper, the hybrid compliance-stiffness matrix method for simulating wave propagation in (delaminated) multilayered media with viscoelastic anisotropy has been confronted with high-quality amplitude and phase experiments on delaminated composites, obtained using the ultrasonic polar scan setup (UPS) in transmission by considering harmonic as well as pulsed ultrasound. Results are presented for multiple thin carbon/epoxy laminates with an artificial edge delamination induced by a foil insert, showing a good agreement between experimental recording and numerical modeling. The obtained results further reveal the feasibility of the harmonic UPS to detect and even locate the depth-position of multiple delaminations in fiber reinforced composites. Considering that the harmonic UPS method does not rely on the detection of different echoes like the classical C-scan, but rather expounds the conditions for efficient stimulation of guided waves in the solid, the method is found to be highly suited for inspecting thin composite materials for the presence of delaminations.

Extraction of bulk wave characteristics from a pulsed ultrasonic polar scan

The pulsed ultrasonic polar scan (P-UPS) technique provides a map with characteristic contours reflecting the critical bulk wave angles, which directly relate to the in-plane elastic properties of the insonified material spot. Besides these contours, additional information is captured in a P-UPS experiment which has particular importance for the inspection of anisotropic materials. By extensive post-processing on a single P-UPS experiment, we successfully extracted the local directional (i) critical bulk wave angles, (ii) phase velocity profiles, (iii) slowness curves, (iv) walk-off angles and (v) energy velocity profiles, for the three different polarization states of bulk waves. The procedure is demonstrated and discussed for an isotropic aluminum sample as well as an autoclave manufactured orthotropic [0]8 carbon/epoxy laminate. In addition, a numerical and experimental investigation of the role of the immersion liquid as a lens for the P-UPS result is performed. This lensing effect permits to zoom in/out on the P-UPS fingerprint, hence broadening the class of materials which can be inspected by the P-UPS technique.

Pitfalls in the experimental recording of ultrasonic (backscatter) polar scans for material characterization

The ultrasonic polar scan (UPS), either in transmission, reflection or backscatter mode, is a promising non-destructive testing technique for the characterization of composites, providing information about the mechanical anisotropy, the viscoelastic damping, the surface roughness, and more. At present, the technique is merely being used for qualitative purposes. The limited quantitative exploration and use of the technique can be primarily ascribed to limitations of current theoretical models as well as the difficulty to perform accurate, and more importantly, reproducible UPS experiments. Over the last years, we have identified several potential pitfalls in the experimental implementation of the technique which severely deteriorate the accurateness and reproducibility of a UPS. In this paper, we make an inventory of the most important difficulties, illustrate each of them by a real experiment and present a feasible mediation, either numerical or experimental in nature. Once the experimental set-up is fine-tuned to overcome these pitfalls, it is expected that the recording of high-level UPS experiments, in combination with numerical computations, will facilitate the technique to become a fully quantitative non-destructive characterization method.

The Pulsed Ultrasonic Backscatter Polar Scan and its Applications for NDT and Material Characterization

In a conventional ultrasonic polar scan (UPS) experiment, the amplitude or time-of-flight-diffraction (TOFD) values of the transmitted and/or reflected acoustic pulse are recorded for a wide range of incidence angles, in view of gaining knowledge about the elastic properties at the insonified material spot. Here we apply the pulsed UPS technique and investigate the backscattered signal, resulting in the ultrasonic backscatter polar scan (UBPS). It is shown that a UPBS contains a blueprint of geometrically related features of the insonified material spot which can be of particular interest for various industrial applications. We applied the UBPS for (i) the determination of the stacking sequence of a cross-ply composite laminate, (ii) the semi-quantification of a multidirectional microscopic surface corrugation, (iii) the detection of corrosion in an early stage as well as (iv) the detection and the localization of a closed surface breaking crack.

Identification of the Elastic Properties of Isotropic and Orthotropic Thin-Plate Materials with the Pulsed Ultrasonic Polar Scan

Already in the early 1980’s, it has been conjectured that the pulsed ultrasonic polar scan (P-UPS) provides a unique fingerprint of the underlying mechanical elasticity tensor at the insonified material spot. Until now, that premise has not been thoroughly investigated, nor validated, despite the opportunities this would create for NDT and materials science in general. In this paper, we report on the first-ever implementation of an inverse modeling technique on the basis of a genetic optimization scheme in order to extract quantitative information from a P-UPS. We validate the optimization approach for synthetic data, and apply it to experimentally obtained polar scans for annealed aluminum, cold rolled DC-06 steel as well as for carbon fiber reinforced plastics. The investigated samples are plate-like and do not require specific preparation. The inverted material characteristics show good agreement with literature, micro-mechanical models as well as with results obtained through conventional testing procedures.

Nondestructive damage assessment in fiber reinforced composites with the pulsed ultrasonic polar scan

This study investigates the use of both amplitude and time-of-flight based pulsed ultrasonic polar scan (P-UPS) as a sophisticated non-destructive damage sensor for fiber reinforced composites. Focus is put on stiffness related damage phenomena, which are in general difficult to monitor nondestructively, and their associated signature in the P-UPS image. Various composite samples, with different damage states, have been inspected at multiple material spots with the P-UPS technique. The results demonstrate the capability of the P-UPS method to obtain a unique signature of the local material damage characteristics. Several indicators in the acquired P-UPS images have been identified from which the type and level of material degradation can be obtained. The P-UPS extracted characteristics are fully supported by simulations, conventional tests as well as visual inspection.

Ultrasonic polar scans: Numerical simulation on generally anisotropic media

Ultrasonic polar scans are based on the recording of the reflected or transmitted amplitude of sound, impinging a fiber reinforced composite from every possible angle of incidence. The mechanical anisotropy of such materials makes the reflection coefficient direction dependent, whence an ultrasonic polar scan forms a fingerprint of the investigated material. Such scans have already proved to be very valuable in the characterization of composites. Simulations have been performed for single layered and multi-layered systems, for pulsed and harmonic waves. Fiber reinforced composites are mostly orthotropic. The current report presents simulations not only on orthotropic materials but on materials of any kind of anisotropy. These extended numerical simulations are not only valuable in the characterization of highly sophisticated composites, but may also be used to characterize thin slices of crystals and even layered crystals.

On the influence of fatigue on ultrasonic polar scans of fiber reinforced composites

Ultrasonic polar scans have already proved to be well-suited as a practical means of characterizing fiber reinforced composite plates. The method consists of registering the reflected or transmitted sound amplitude as a function of each possible angle of incidence. It is hence an amplitude measurement by which it differs from more common `time of flight' measurements. Ultrasonic polar scans are actually a fingerprint of a composite laminate. One of the many promising applications of the ultrasonic polar scan is the monitoring of fiber reinforced composites in service. Especially the progress of fatigue damage can be monitored easily and nondestructively. This paper presents numerical simulations of the influence of fatigue on ultrasonic polar scans as well as some experimental results.