Error analysis of self-compensated ultrasound measurements of the thickness loss due to corrosion in pipe walls.

The ultrasonic pulse-echo technique is widely employed to measure the wall thickness reduction due to corrosion in pipelines. Ultrasonic monitoring is noninvasive and can be performed online to evaluate the structural health of pipelines. Although ultrasound is a robust technique, it presents two main difficulties arising from the temperature variation in the medium being monitored: the mechanical assembly must have high stability and the ultrasonic propagation velocity must take into account the temperature variation. In this paper, a detailed strategy is presented to compensate for changes in the propagation velocity whenever the temperature changes. The method is considered self-compensated because the calibration data is obtained from the ultrasonic signals captured using the pipe under evaluation. The analysis of systematic errors in the temperature compensation is presented, first considering that a reference initial pipe thickness is given, and second when a reference sound velocity is given. The technique was evaluated under laboratory conditions using a closed loop with accelerated corrosion through the use of continuous flow saline water containing sand. In this test, the ultrasonic results were compared with the traditional coupon method used to determine corrosion loss. The results show that the self-compensated method was able to compensate for temperature fluctuations, and the total thickness loss measured by the ultrasound technique was close to the value measured by the coupons. Finally, the measurement system was tested in a production pipeline exposed to sunlight. The results show that the self-compensated method can reduce the oscillations in the thickness loss readings, caused by temperature swings, but large temperature variations cannot be completely compensated for. This experiment also shows the effects of low mechanical stability, which caused completely invalid results.

Self-compensation methodology for ultrasonic thickness gauges.

There are many causes for the reduction of the thickness in pipelines, tanks and other mechanical structures. Corrosion, erosion, and abrasive wear cause degradation of mechanical structures and decrease their lifespan. These can be very slow processes that are difficult to track over time. Thickness gauging monitoring is commonly used as a way of preventive maintenance. The pulse-echo ultrasound can be a suitable technique to measure the thickness diminution in industrial facilities. Although ultrasound is considered a robust technique, in this particular application it presents two main difficulties: the mechanical stability of the assembly and the variation of the ultrasonic speed over time. Both mechanical assembly and acoustic propagation speed are strongly influenced by the temperature. In this paper, the implementation of a methodology that compensates for the temperature influences on the ultrasonic speed and the mechanical assembly is presented. The methodology can be applied in metallic structures to evaluate corrosion over long time periods. The temperature compensation data is obtained from the analysis of the ultrasonic signals. In this sense, the method can be called self-compensated. As initial data for the determination of thickness changes, the ultrasonic speed in the material at a reference temperature must be known. All results are evaluated at this temperature. An analysis of the uncertainty sources and limitations of the methodology is also included. To show the experimental application of the proposed technique, a rigid sample was designed in order to avoid mechanical instability. The results show that the methodology can compensate for the temperature, detecting a thickness reduction in the order of a few micrometers.

Acoustic levitation of an object larger than the acoustic wavelength.

Levitation and manipulation of objects by sound waves have a wide range of applications in chemistry, biology, material sciences, and engineering. However, the current acoustic levitation techniques are mainly restricted to particles that are much smaller than the acoustic wavelength. In this work, it is shown that acoustic standing waves can be employed to stably levitate an object much larger than the acoustic wavelength in air. The levitation of a large slightly curved object weighting 2.3 g is demonstrated by using a device formed by two 25 kHz ultrasonic Langevin transducers connected to an aluminum plate. The sound wave emitted by the device provides a vertical acoustic radiation force to counteract gravity and a lateral restoring force that ensure horizontal stability to the levitated object. In order to understand the levitation stability, a numerical model based on the finite element method is used to determine the acoustic radiation force that acts on the object.

Experimental study of the oscillation of spheres in an acoustic levitator.

The spontaneous oscillation of solid spheres in a single-axis acoustic levitator is experimentally investigated by using a high speed camera to record the position of the levitated sphere as a function of time. The oscillations in the axial and radial directions are systematically studied by changing the sphere density and the acoustic pressure amplitude. In order to interpret the experimental results, a simple model based on a spring-mass system is applied in the analysis of the sphere oscillatory behavior. This model requires the knowledge of the acoustic pressure distribution, which was obtained numerically by using a linear finite element method (FEM). Additionally, the linear acoustic pressure distribution obtained by FEM was compared with that measured with a laser Doppler vibrometer. The comparison between numerical and experimental pressure distributions shows good agreement for low values of pressure amplitude. When the pressure amplitude is increased, the acoustic pressure distribution becomes nonlinear, producing harmonics of the fundamental frequency. The experimental results of the spheres oscillations for low pressure amplitudes are consistent with the results predicted by the simple model based on a spring-mass system.

Nonlinear characterization of a single-axis acoustic levitator.

The nonlinear behavior of a 20.3 kHz single-axis acoustic levitator formed by a Langevin transducer with a concave radiating surface and a concave reflector is experimentally investigated. In this study, a laser Doppler vibrometer is applied to measure the nonlinear sound field in the air gap between the transducer and the reflector. Additionally, an electronic balance is used in the measurement of the acoustic radiation force on the reflector as a function of the distance between the transducer and the reflector. The experimental results show some effects that cannot be described by the linear acoustic theory, such as the jump phenomenon, harmonic generation, and the hysteresis effect. The influence of these nonlinear effects on the acoustic levitation of small particles is discussed.

Strain sensitivity model for guided waves in plates using the time-reversal technique.

The use of the time-reversal technique to detect variations in the external applied traction in a strip of aluminum plate is presented. Experiments have been performed in transmission-reception mode, using two fixed ultrasonic transducers near the ends of the plate. Two different parameters of the time-reversed signal are used for monitoring the strain state, the peak amplitude and the focusing time. The inverse filter technique was used in the transmitted signal to equalize the amplitude spectrum, enhancing the sensitivity in the focus amplitude by 5 times. The external traction sensitivity was experimentally verified by using an aluminum plate (800 × 100 × 3 mm) and two 5-MHz ultrasonic transducers spaced 700 mm apart. At the maximum strain state (180 µstrain), the peak value was reduced by about 10% in the conventional process and by 50% using the inverse filter. To evaluate the effects of the strain in the time-reversal signal, a theoretical model was constructed. This model is successful in predicting the changes in the group delay and, consequently, the focusing time using a linear equation. This relationship can also be used to determine the strain level quantitatively. The experimental results show that the time-reversal signal technique can be used in practical monitoring of changes at the strain level in mechanical structures.

Matrix method for acoustic levitation simulation.

A matrix method is presented for simulating acoustic levitators. A typical acoustic levitator consists of an ultrasonic transducer and a reflector. The matrix method is used to determine the potential for acoustic radiation force that acts on a small sphere in the standing wave field produced by the levitator. The method is based on the Rayleigh integral and it takes into account the multiple reflections that occur between the transducer and the reflector. The potential for acoustic radiation force obtained by the matrix method is validated by comparing the matrix method results with those obtained by the finite element method when using an axisymmetric model of a single-axis acoustic levitator. After validation, the method is applied in the simulation of a noncontact manipulation system consisting of two 37.9-kHz Langevin-type transducers and a plane reflector. The manipulation system allows control of the horizontal position of a small levitated sphere from -6 mm to 6 mm, which is done by changing the phase difference between the two transducers. The horizontal position of the sphere predicted by the matrix method agrees with the horizontal positions measured experimentally with a charge-coupled device camera. The main advantage of the matrix method is that it allows simulation of non-symmetric acoustic levitators without requiring much computational effort.

Identification of elastic, dielectric, and piezoelectric constants in piezoceramic disks.

Three-dimensional modeling of piezoelectric devices requires a precise knowledge of piezoelectric material parameters. The commonly used piezoelectric materials belong to the 6mm symmetry class, which have ten independent constants. In this work, a methodology to obtain precise material constants over a wide frequency band through finite element analysis of a piezoceramic disk is presented. Given an experimental electrical impedance curve and a first estimate for the piezoelectric material properties, the objective is to find the material properties that minimize the difference between the electrical impedance calculated by the finite element method and that obtained experimentally by an electrical impedance analyzer. The methodology consists of four basic steps: experimental measurement, identification of vibration modes and their sensitivity to material constants, a preliminary identification algorithm, and final refinement of the material constants using an optimization algorithm. The application of the methodology is exemplified using a hard lead zirconate titanate piezoceramic. The same methodology is applied to a soft piezoceramic. The errors in the identification of each parameter are statistically estimated in both cases, and are less than 0.6% for elastic constants, and less than 6.3% for dielectric and piezoelectric constants.

Ultrasonic viscosity measurement using the shear-wave reflection coefficient with a novel signal processing technique.

Real-time viscosity measurement remains a necessity for highly automated industry. To resolve this problem, many studies have been carried out using an ultrasonic shear wave reflectance method. This method is based on the determination of the complex reflection coefficient's magnitude and phase at the solid-liquid interface. Although magnitude is a stable quantity and its measurement is relatively simple and precise, phase measurement is a difficult task because of strong temperature dependence. A simplified method that uses only the magnitude of the reflection coefficient and that is valid under the Newtonian regimen has been proposed by some authors, but the obtained viscosity values do not match conventional viscometry measurements. In this work, a mode conversion measurement cell was used to measure glycerin viscosity as a function of temperature (15 to 25 degrees C) and corn syrup-water mixtures as a function of concentration (70 to 100 wt% of corn syrup). Tests were carried out at 1 MHz. A novel signal processing technique that calculates the reflection coefficient magnitude in a frequency band, instead of a single frequency, was studied. The effects of the bandwidth on magnitude and viscosity were analyzed and the results were compared with the values predicted by the Newtonian liquid model. The frequency band technique improved the magnitude results. The obtained viscosity values came close to those measured by the rotational viscometer with percentage errors up to 14%, whereas errors up to 96% were found for the single frequency method.

Computational method to determine reflected ultrasonic signals from arbitrary-geometry targets.

A computational method based on the impulse response and on the discrete representation computational concept is proposed for the determination of the echo responses from arbitrary-geometry targets. It is supposed that each point of the transducer aperture can be considered as a source radiating hemispherical waves to the reflector. The local interaction with each of the hemispherical waves at the reflector surface can be modeled as a plane wave impinging on a planar surface, using the respective reflection coefficient. The method is valid for all field regions and can be performed for any excitation waveform radiated from an arbitrary acoustic aperture. The effects of target geometry, position, and material on both the amplitude and the shape of the echo response are studied. The model is compared with experimental results obtained using broadband transducers together with plane and cylindrical concave rectangular reflectors (aluminum, brass, and acrylic), as well as a circular cavity placed on a plane surface, in a water medium. The method can predict the measured echoes accurately. This paper shows an improved approach of the method, considering the reflection coefficient for all incident hemispherical waves arriving at each point of the target surface.

Finite element analysis and optimization of a single-axis acoustic levitator.

A finite element analysis and a parametric optimization of single-axis acoustic levitators are presented. The finite element method is used to simulate a levitator consisting of a Langevin ultrasonic transducer with a plane radiating surface and a plane reflector. The transducer electrical impedance, the transducer face displacement, and the acoustic radiation potential that acts on small spheres are determined by the finite element method. The numerical electrical impedance is compared with that acquired experimentally by an impedance analyzer, and the predicted displacement is compared with that obtained by a fiber-optic vibration sensor. The numerical acoustic radiation potential is verified experimentally by placing small spheres in the levitator. The same procedure is used to optimize a levitator consisting of a curved reflector and a concave-faced transducer. The numerical results show that the acoustic radiation force in the new levitator is enhanced 604 times compared with the levitator consisting of a plane transducer and a plane reflector. The optimized levitator is able to levitate 3, 2.5-mm diameter steel spheres with a power consumption of only 0.9 W.

Viscosity measurement of Newtonian liquids using the complex reflection coefficient.

This work presents the implementation of the ultrasonic shear reflectance method for viscosity measurement of Newtonian liquids using wave mode conversion from longitudinal to shear waves and vice versa. The method is based on the measurement of the complex reflection coefficient (magnitude and phase) at a solid-liquid interface. The implemented measurement cell is composed of an ultrasonic transducer, a water buffer, an aluminum prism, a PMMA buffer rod, and a sample chamber. Viscosity measurements were made in the range from 1 to 3.5 MHz for olive oil and for automotive oils (SAE 40, 90, and 250) at 15 and 22.5 degrees C, respectively. Moreover, olive oil and corn oil measurements were conducted in the range from 15 to 30 degrees C at 3.5 and 2.25 MHz, respectively. The ultrasonic measurements, in the case of the less viscous liquids, agree with the results provided by a rotational viscometer, showing Newtonian behavior. In the case of the more viscous liquids, a significant difference was obtained, showing a clear non-Newtonian behavior that cannot be described by the Kelvin-Voigt model.