Ultrasonic Wave Testing Research Articles

Evaluating Pipeline Inspection Technologies for Enhanced Corrosion Detection in Mining Water Transport Systems

Water transport pipelines in the mining industry face significant corrosion challenges due to extreme environmental conditions, such as arid climates, temperature fluctuations, and abrasive soils. This study evaluates the effectiveness of three advanced inspection technologies—Guided Wave Ultrasonic Testing (GWUT), Metal Magnetic Memory (MMM), and In-Line Inspection (ILI)—in maintaining pipeline integrity under such conditions. A structured methodology combining diagnostic assessment, technology research, and comparative evaluation was applied, using key performance indicators like detection capability, operational impact, and feasibility. The results show that GWUT effectively identifies surface anomalies and wall thinning over long pipeline sections but faces depth and diameter limitations. MMM excels at detecting early-stage stress and corrosion in inaccessible locations, benefiting from minimal preparation and strong market availability. ILI provides comprehensive internal and external assessments but requires piggable pipelines and operational adjustments, limiting its use in certain systems. A case study of critical aqueducts of mining site water supply illustrates real-world technology selection challenges. The findings underscore the importance of an integrated inspection approach, leveraging the complementary strengths of these technologies to ensure reliable pipeline integrity management. Future research should focus on quantitative performance metrics and cost-effectiveness analyses to optimize inspection strategies for mining infrastructure.

Measurement Method of Stress in High-Voltage Cable Accessories Based on Ultrasonic Longitudinal Wave Attenuation.

High-voltage cables are the main arteries of urban power supply. Cable accessories are connecting components between different sections of cables or between cables and other electrical equipment. The stress in the cold shrink tube of cable accessories is a key parameter to ensure the stable operation of the power system. This paper attempts to explore a method for measuring the stress in the cold shrink tube of high-voltage cable accessories based on ultrasonic longitudinal wave attenuation. Firstly, a pulse ultrasonic longitudinal wave testing system based on FPGA is designed, where the ultrasonic sensor operates in a single-transmit, single-receive mode with a frequency of 3 MHz, a repetition frequency of 50 Hz, and a data acquisition and transmission frequency of 40 MHz. Then, through experiments and theoretical calculations, the transmission and attenuation characteristics of ultrasonic longitudinal waves in multi-layer elastic media are studied, revealing an exponential relationship between ultrasonic wave attenuation and the thickness of the cold shrink tube. Finally, by establishing a theoretical model of the radial stress of the cold shrink tube, using the thickness of the cold shrink tube as an intermediate variable, an effective measurement of the stress of the cold shrink tube was achieved.

Study on ultrasonic lamb wave testing technology of honeycomb sandwich structures

Abstract Honeycomb sandwich composite panels have complex structures, large sizes, many types of defects, and significant sound attenuation, which lead to low efficiency and poor sensitivity of ultrasonic non-destructive testing. In the study, a non-linear ultrasonic lamb wave testing technique for honeycomb sandwich composite panels is proposed. Firstly, the anisotropic propagation characteristics and modal structure of lamb waves in honeycomb sandwich composite panels are analyzed, and the lamb wave modes with non-linear ultrasonic accumulation are excited. Secondly, the data extraction method and imaging algorithm of non-linear ultrasonic lamb wave imaging testing are proposed. Finally, an enhanced imaging algorithm is proposed to improve image quality based on the sliding window algorithm. Based on the comparative analysis of air-coupled ultrasonic testing images and metallographic tests, it can be seen that non-linear ultrasonic lamb wave testing signals can be used to characterize the damage distribution characteristics of honeycomb sandwich composite panels, display debonding and weak debonding defects, and have the advantages of being able to perform on the same side testing and high efficiency, which can be used for non-destructive testing of honeycomb sandwich composite panels.

Research on the Effect Mechanism of Re on Interface Dislocation Networks of Ni-Based Single Crystal Alloys.

The effect of interface dislocation networks on the mechanical properties of new Ni-based single crystal alloys containing Rhenium (Re) is very large. Because the interface dislocations are microscopic in the nano-scale range, this has not been investigated, and it is very difficult to prepare new Ni-based single crystal alloys containing Re. Therefore, six kinds of new Ni-based single crystal alloys containing Re were prepared, and the hardness tests and nonlinear ultrasonic lamb wave tests were performed on the samples. It was found that the density of interface dislocation networks increases with the increase in the content of Re, which improves the blocking ability of matrix phase dislocation cutting into precipitated phase and enhances the inhibition of dislocation movement. The nonlinear ultrasonic lamb wave tests showed that the materials exhibit better mechanical properties when the density of the interface dislocation networks increases. Meanwhile, a new molecular dynamics model which is closer to the real state of an Ni-based single crystal alloy was constructed to reveal the evolution mechanism of interface dislocation networks. The results showed that the potential energy of Re atoms at the interface is the lowest, which affects the reduction of the potential energy of other atoms at the interface, and thus the stability of the model is improved. In addition, according to the change in the total length of dislocation loops in the model system, with the increase in the content of Re atoms, the inhibition of dislocation movement by dislocation networks at the interface is strengthened.

Detection of internal crack growth in polyethylene pipe using guided wave ultrasonic testing

Detection of internal crack growth in polyethylene pipe using guided wave ultrasonic testing

Study on Corrosion Monitoring of Reinforced Concrete Based on Longitudinal Guided Ultrasonic Waves

The corrosion of reinforced concrete (RC) is one of the most serious durability problems in civil engineering structures, and the corrosion detection of internal reinforcements is an important basis for structural durability assessment. In this paper, the appropriate frequency required to cause excitation signals in the specimen is first analyzed by means of frequency dispersion curves. Subsequently, the effectiveness of five damage indexes (DIs) is discussed using random corrosion in finite elements. Finally, guided ultrasonic wave (GUW) tests are conducted on reinforcement and RC specimens at different corrosion degrees, and the test results are verified using a theoretical corrosion model. The results show that the larger the covered thickness is at the same frequency, the higher the modal order of the GUW in the frequency dispersion curve is, and the smaller the group velocity is. The SAD is the most sensitive to the corrosion state of the reinforcement compared with the other DIs, and it shows a linear increasing trend with the increase in the corrosion degree of the reinforcement. The SAD values of the RC specimens showed a three-stage change with the increase in the corrosion time, and the time until the appearance of corrosion cracks was increased with the increase in the covered thickness. It can be seen that increasing the covered thickness is an effective method to delay the time until the appearance of corrosion cracks in RC specimens.

Effect of self-healing behavior and self-healing technologies on the structural characteristics of cracked RC/ECC composite beams

The improving potential of self-healing behavior and self-healing technology to degradation of structural characteristics of cracked reinforced concrete structures was explored at the member level. Reinforced concrete/engineered cementitious composite (RC/ECC) composite beams were prepared by three self-healing technologies, including crystalline additives (CA), two types of superabsorbent polymers (SAP), and beam without self-healing technology was used as reference specimens. The self-healing properties of structural characteristics of beams were studied by four-point bending tests, including bear capacity, stiffness, ductility index, energy absorption capacity (EAC), and failure mode. The self-healing behavior of damage was evaluated by ultrasonic wave test and damage identification test based on natural frequency. Self-healing behavior of four types of RC/ECC composite beams improved the structural characteristics after cracking to varying degrees. The stiffness of CB-0, CB-S, CB-C, and CB-SH after self-healing increased by 10.80%, 22.88%, 36.71%, and 28.80% compared to that without self-healing, respectively. Recovery ability of structural characteristics of RC/ECC composite beam is enhanced by self-healing technologies. Moreover, CA exhibits a superior improvement in the recovery ability of the structural characteristics compared with two types of SAP. Moreover, the natural frequency and ultrasonic velocity of pre-cracked beams after self-healing were higher than those without self-healing, especially when self-healing technologies were applied. There is a positive correlation between the recovery ability of ultrasonic velocity and self-healing behavior of the structural characteristics of RC/ECC composite beams. This also explains why the structural characteristics of pre-cracked beams have been improved to varying degrees due to different self-healing techniques.

Strength Investigation of Slag-Based Geopolymer Composites Incorporating Different Amounts of Colemanite Waste and Silica Fume Under Different Exposure Conditions

In this study, it is aimed to investigate the strength performance of slag-based geopolymer mortar with different percentages of silica fume and colemanite waste by mixing Na₂SiO₃ and NaOH as the alkaline activator for the geopolymerization reaction, and cured at room temperature were prepared, in terms of compressive strength, flexural strength, ultrasonic pulse velocity and freeze-thaw resistance parameters. Five different mixtures were prepared by using different amounts of silica fume and colemanite waste by using the same amount of ground granulated blast furnace slag, sand and 8M sodium hydroxide for these five mixtures. The mixture, including a paste proportion of 20% slag, 40% colemanite waste, and 40% silica fume, was used as a control mix. The maximum compressive strength (21.24 MPa, 38.32 MPa) flexural strength (5.86 MPa, 6.98), weight loss caused by freeze-thaw effect (0.56%) and ultrasonic pulse wave test (3082 m/s) results were noted as for 7th and 28th day, respectively. After -60 cycles [1 cycle consists of (-18 oC) for 90 minutes and (+4 oC) for 30 minutes], the maximum compressive and flexural strength was observed as (40.18 MPa and 4.92 MPa, respectively). The results indicated that the strength results were consistently increased as silica fume increased. The addition of a certain amount of silica fume gave promising results both in terms of the strength and durability aspects. Overall, according to this experimental study, the utilization of 30% colemanite waste and 50% silica fume can be recommended so as to balance both sustainability and engineering aspects.

Propagation characteristics of ultrasonic in SLM manufactured AlSi10Mg

Porosity is a crucial quality evaluation criterion in metal additive manufacturing. To investigate the propagation characteristics of ultrasonic longitudinal waves with different incident frequencies in AlSi10Mg prepared by selective laser melting, specimens with varying porosity were created using printing process adjustments. Ultrasonic longitudinal wave tests and COMSOL simulations based on 2.5 MHz, 3.5 MHz, 5 MHz, and 7.5 MHz incident frequencies were carried out to establish a linear relationship between average wave velocity, average attenuation coefficient, and porosity at different frequencies. Results indicate that sound velocity and porosity are inversely proportional for each frequency longitudinal wave, while the attenuation coefficient is proportional to the porosity. Linear fitting expressions suggest that the best fit for both sound velocity and attenuation coefficient occurs at 5 MHz. Simulation results demonstrate that using 5 MHz as the incident frequency can better balance detection sensitivity and linearity. These findings provide more data support for establishing the intrinsic connection between acoustic parameters and porosity of AlSi10Mg prepared by selective laser melting in the selected area and serve as a reference for selecting ultrasonic incident frequencies in practical inspection.

A comparative study for determining rock joint normal stiffness with destructive uniaxial compression and nondestructive ultrasonic wave testing

Rock joint a kind of vital discontinuities in natural rock mass. How to accurately and conveniently determine joint normal stiffness is therefore significant in rock mechanics. Here, first, seven existing methods for determining joint normal stiffness were introduced and reviewed, among which Method I (the indirect measurement method), Method II (the direct determination method), Method III (the across-joint strain gauge measurement method) and Method IV (the deformation measuring ring method) are via destructive uniaxial compression testing, while Method V (the best fitting method), Method VI (the rapid evaluation method) and Method VII (the effective modulus method) are through wave propagation principles and nondestructive ultrasonic testing. Subsequently, laboratory tests of intact and jointed sandstone specimens were conducted following the testing requirements and procedures of those seven methods. A comparison among those methods was then performed. The results show that Method I, i.e. the benchmark method, is reliable and stable. Method II has a conceptual drawback, and its accuracy is acceptable at only very low stress levels. Relative errors in the results from Method III are very large. With Method IV, the testing results are sufficiently accurate despite the strict testing environment and complicated testing procedures. The results from Method V are greatly unstable and significantly dependent on the natural frequency of the transducers. The joint normal stiffness determined with Method VI is stable and accurate, although data processing is complex. Method VII could be adopted to determine the joint normal stiffness corresponding to the rock elastic deformation phase only. Consequently, it is suggested that Methods I, IV and VI should be adopted for the measurement of joint normal stiffness. The findings could be helpful in selecting an appropriate method to determine joint normal stiffness and, hence, to better solve discontinuous rock mass problems.

Guided Wave Ultrasonic Testing for Crack Detection in Polyethylene Pipes: Laboratory Experiments and Numerical Modeling.

The use of guided wave-based Ultrasonic Testing (UT) for monitoring Polyethylene (PE) pipes is mostly restricted to detecting defects in welded zones, despite its diversified success in monitoring metallic pipes. PE's viscoelastic behavior and semi-crystalline structure make it prone to crack formation under extreme loads and environmental factors, which is a leading cause of pipeline failure. This state-of-the-art study aims to demonstrate the potential of UT for detecting cracks in non-welded regions of natural gas PE pipes. Laboratory experiments were conducted using a UT system consisting of low-cost piezoceramic transducers assembled in a pitch-catch configuration. The amplitude of the transmitted wave was analyzed to study wave interaction with cracks of different geometries. The frequency of the inspecting signal was optimized through wave dispersion and attenuation analysis, guiding the selection of third- and fourth- order longitudinal modes for the study. The findings revealed that cracks with lengths equal to or greater than the wavelength of the interacting mode were more easily detectable, while smaller crack lengths required greater crack depths for detection. However, there were potential limitations in the proposed technique related to crack orientation. These insights were validated using a finite element-based numerical model, confirming the potential of UT for detecting cracks in PE pipes.

Investigation of micro-structure and compression behavior of cement mortar with artificial geopolymer sand

An artificial alternative material for natural sand in construction is of significance for the civil engineering. In the present study, the effects of artificial geopolymer sand (AGS) as an alternative to natural sand (NS) on pore structure and mechanical property of cement mortar were studied. First, six groups of cement mortar specimens were prepared with the different replacement ratios (0.0%, 20.0%, 40.0%, 60.0%, 80.0% and 100.0%). Then, a series of nuclear magnetic resonance (NMR) tests were performed to study the effects of replacement ratio on the density, total porosity and percentage of different size pores. Finally, the ultrasonic wave and uniaxial compressive tests were performed to study the effects of replacement ratio on the P-wave velocity, strength and elastic modulus. The results show that the density and P-wave velocity decrease linearly as the replacement ratio increases. The total porosity increases slowly at first and then increases rapidly as the replacement ratio increases. The increase in replacement ratio induces the more significant increase in the smaller pores compared with the larger pores. The strength and elastic modulus firstly increase and then decrease as the replacement ratio increases. The strength and elastic modulus decreased by 11.0% and 5.4% when replacement ratio reaches 100%.

Study on dynamic mechanical properties and constitutive model of granite under constant strain rate loading

A systemic understanding of the dynamic mechanical properties and dynamic constitutive model of granite is of great significance to the study of natural disaster prevention and protection of granite buildings. In the present study, constant strain rate loading tests of granite specimens under different impact velocities were carried out by using a shop-fabricated cylindrical conical striker and split Hopkinson pressure bar (SHPB) test system. The compressive strength of granite material increases with the strain rate, and therefore, a continuously smooth uniaxial dynamic strength criterion suitable for describing the changes in the dynamic increase factor (DIF) with strain rate was proposed and tested. The granite specimen under impact loading was intact when the strain rate was lower than 80 s−1, cracked when it was 80 to 90 s−1, fractured when it was 90 to 135 s−1, and crushed when it was over 135 s−1. Ultrasonic wave tests were performed to evaluate the damage caused by impact, and the quantitative relationship between the damage value and peak stress was established based on regression analysis. The results showed that the stress threshold causing damage was 50.15 MPa with a corresponding strain rate of 31.7 s−1 and a peak strain of 3670 microstrain. A new constitutive model describing the dynamic mechanical properties of granite was developed based on a nonlinear viscoelastic model (the ZWT model), and the constitutive parameters were then determined. A user-defined material subroutine named VUMAT of ABAQUS finite element software was applied to describe the established constitutive model and simulate the impact process of granite. The results confirmed that the developed constitutive model can well describe the prepeak dynamic mechanical properties of granite under impact compression.

Monitoring evolution of debris-filled damage using pre-modulated wave and guided wave ultrasonic testing (GWUT)

Metals are essentially used to construct structures of high economic importance, but their service life is shortened by damage such as crack, corrosion, cavity, and dents. Damage to structure causes gradual degradation of its strength and compromises its load-carrying capacity. Some damage could be designed against but pitting corrosion, especially when it is filled with debris that would hide it and deepen its perforation activities. In this work, monitoring the evolution of debris-filled damage in structure is studied using pre-modulated wave and guided wave ultrasonic testing (GWUT). The structural responses in the varying percentage of debris-filled damage were processed using Fast Fourier Transform (FFT), Hilbert Transform (HT) and correlation techniques. The regression analysis of debris-filled damage resulted in empirical predictive models that could detect the damage and percentage of debris that might have filled it with average percentage errors of 1.34 and 0.21, respectively. The debris in the damage caused an overmodulation of the high-frequency signal. The intensity of the lower sideband (LSB) was observed to be very sensitive to variations in the damage than the upper sideband (USB). The transmission power efficiency of modulation sidebands increased proportionally with debris-filled damage percentage and could serve as a damage index.

Monitoring of mechanical changes in a pipe assembly with complex geometry using multi-mode acoustic signals

Guided wave ultrasonic testing has been widely used for nondestructive and long-range evaluation of diverse mechanical structures, such as pipes and plates. In general, a large number of guided wave modes exist even in the simplest geometries, and they exhibit highly dispersive characteristics. Thus, sophisticated excitation methods and elaborate modal analyses need to be implemented to excite, acquire, and process well-defined pure modes as part of such a measurement method. If the interrogated structure has complex geometry, for example, with cross-sectional variations or multiple joints, the utilization of pure modes becomes significantly more difficult. To overcome this difficulty, this paper proposes the use of multi-mode, multi-frequency guided waves for long-range inspection of structures with arbitrarily complex geometries. Using broadband chirp signals and multi-mode time–frequency analysis in a prototypical complex pipe assembly that includes multiple pipe diameters, elbows, and flange connections, we experimentally show sensitive detection of mechanical changes (both material addition and loss). In addition, we demonstrate that the complexity of the structure can be modeled in the digital domain with sufficient detail to allow accurate numerical simulation of the acoustic response using this method.

Relationships between Physical, Mechanical and Acoustic Properties of Asphalt Mixtures Using Ultrasonic Testing

Ultrasonic testing can be used for a nondestructive and rapid determination of material properties. In this study, twelve asphalt mixture samples of four different types were fabricated and used in conventional material property tests and two ultrasonic wave tests. Physical properties such as bulk specific gravity and air void content, mechanical properties such as dynamic modulus and phase angle, and acoustic properties such as wave velocity were measured. Relationships between these properties were established and analyzed as a tool for the future material property determination. In addition, the dynamic modulus and phase angle, measured in a standard laboratory test, were used to construct two master curve models to predict their values at arbitrary temperatures and frequencies. Furthermore, a theoretical model for wave velocity in a linear isotropic viscoelastic material was utilized with measured density, Poisson’s ratio, phase angle and ultrasonic wave velocity to predict the dynamic modulus. Good agreement has been achieved between laboratory measurements and model predictions. It indicates that ultrasonic testing can serve as a rapid method for material property determination.

Degradation of Mechanical Behavior of Sandstone under Freeze-Thaw Conditions with Different Low Temperatures

This study investigated the effects of freezing temperature under freeze-thaw cycling conditions on the mechanical behavior of sandstone. First, the sandstone specimens were subjected to 10-time freeze-thaw cycling treatments at different freezing temperatures (−20, −40, −50, and −60 °C). Subsequently, a series of density, ultrasonic wave, and static and dynamic mechanical behavior tests were carried out. Finally, the effects of freezing temperature on the density, P-wave velocity, stress–strain curves, static and dynamic uniaxial compressive strength, static elastic modulus, and dynamic energy absorption of sandstone were discussed. The results show that the density slightly decreases as temperature decreases, approximately by 1.0% at −60 °C compared with that at 20 °C. The P-wave velocity, static and dynamic uniaxial compressive strength, static elastic modulus, and dynamic energy absorption obviously decrease. As freezing temperature decreases from 20 to −60 °C, the static uniaxial compressive strength, static elastic modulus, dynamic strength, and dynamic energy absorption of sandstone decrease by 16.8%, 21.2%, 30.8%, and 30.7%, respectively. The dynamic mechanical behavior is more sensitive to the freezing temperature during freeze-thawing cycling compared with the static mechanical behavior. In addition, a higher strain rate can induce a higher dynamic strength and energy absorption.

Investigation on Biocompatibility and Mechanical Properties of Ti15Mg Alloy

In this research work, bioactive Ti15Mg alloy was prepared by powder metallurgy route to investigate its biocompatibility and mechanical properties. Many tests were performed including X-ray diffraction; optical microscope analysis, scanning electron microscope analysis, ultrasonic wave test, corrosion behavior test, Static immersion test, and the wet sliding wear test. The XRD result shows that the prepared alloy sample consist of (α-Ti phase) and Mg. The microstructure of the prepared alloy sample consisted of a biodegradable Mg or pore and alpha titanium. The effect of the Mg content on degradability was tested based on simulated body fluid of Ringer solutions using electrochemical corrosion. The findings indicate that an elastic modulus of 47GPa exhibits the alloy. There were low corrosion rates of the alloy. The Ti matrix remained integrity after 14 days of immersion in the Ringer solutions, and the magnesium phase dissolved in the solution, causing a layer to form on the alloy. The wear behavior of the prepared ally at wet sliding conditions was evaluated using pin on disc method. The in vitro analysis showed good biocompatibility with Ti15Mg alloy. The prepared alloy demonstrates good biocompatibility and bioactivity.

Rheological Properties of Ultra-Fine Tailings Cemented Paste Backfill under Ultrasonic Wave Action

Ultra-fine tailings cemented paste backfill (UCPB) exhibits special rheological characteristics with the effect of an ultrasonic sound field. In this study, in order to explore the thickening effect of slurry under ultrasonic wave action, we examined the rheological properties with ultrasonic wave tests of UCPB and the rheological properties after ultrasonic wave tests of UCPB. We found that the rheological curve of the slurry changed; the Herschel–Bulkley (HB) model in the initial state transformed into the Bingham model under the action of ultrasound. Ultrasonic waves have a positive effect on reducing slurry viscosity and yield stress. The rheological test of the slurry with ultrasonic wave action had a positive effect on significantly reducing the apparent viscosity and initial yield stress of slurry with a 62% mass concentration. The rheological test of slurry with ultrasonic wave action and the rheological test after ultrasonic wave action both have positive effects on reducing the viscosity and yield stress of the slurry with a 64% to 68% mass concentration; the overall effect of reducing the viscosity and yield stress of UCPB is greater after ultrasonic wave action of UCPB.

Experimental study on the porosity evaluation of pervious concrete by using ultrasonic wave testing on surfaces

This research conducts two experiments (Experiments I and II) to determine methods for estimating the porosity of pervious concrete (PC) using ultrasonic wave testing. In Experiment I, the ultrasonic wave propagation on the PC surface (surface method), which can be applied during onsite PC construction, was focused on estimating the porosity of PC and the testing method itself. In Experiment II, the effect of specimen thickness on the ultrasonic wave velocity of PC was investigated. Results deduced that the quantitative relationship between ultrasonic wave velocity and PC porosity can be approximated by a quadratic function. It was confirmed that the ultrasonic wave velocity (surface method) was not affected by the thickness of the PC specimen. Therefore, as a conclusion from the results, the porosity of onsite PC construction may be estimated by using the measured ultrasonic wave velocity (surface method) according to the procedure proposed in this article (see Fig. 19 in the article in detail for the porosity estimating procedure).