Analysis of Flaw Detection Sensitivity of Phased Array Ultrasonics in Austenitic Steel Welds According to Inspection Conditions.

The anisotropy and inhomogeneity exhibited by austenitic steel in welds poses a challenge to nondestructive testing employing ultrasonic waves, which is predominantly utilized for the inspection of welds in power plants. In this study, we assess the reliability of phased array ultrasonic testing (PAUT) by analyzing the flaw detection sensitivity of ultrasonic beams in anisotropic welds, based on the inspection conditions. First, we simulated the sectorial scan technique, frequently employed for the inspection of actual welds, while taking into account the ultrasonic wave mode, frequency, and shape and position of a flaw. Subsequently, we analyzed the flaw sensitivity by comparing A-scan signals and S-scan results. The sensitivity analysis results confirmed the detection of all flaws by considering at least two inspection methods based on the shape and position of the flaw. Furthermore, we verified our model by performing an experiment under the same conditions as the simulation and found that the results were in agreement. Hence, we find that the simulation modeling technique proposed in this study can be utilized to develop suitable inspection conditions, according to the flaw characteristics or inspection environment.

Absolute Measurement of Material Nonlinear Parameters Using Noncontact Air-Coupled Reception.

Nonlinear ultrasound is often employed to assess microdamage or nonlinear elastic properties of a material, and the nonlinear parameter is commonly used to quantify damage sate and material properties. Among the various factors that influence the measurement of nonlinear parameters, maintaining a constant contact pressure between the receiver and specimen is important for repeatability of the measurement. The use of an air-coupled transducer may be considered to replace the contact receiver. In this paper, a method of measuring the relative and absolute nonlinear parameters of materials is described using an air-coupled transducer as a receiver. The diffraction and attenuation corrections are newly derived from an acoustic model for a two-layer medium and the nonlinear parameter formula with all corrections is defined. Then, we show that the ratio of the relative nonlinear parameter of the target sample to the reference sample is equal to that of the absolute nonlinear parameter, and this equivalence is confirmed by measurements on three systems of aluminum samples. The proposed method allows the absolute measurement of the nonlinear parameter ratio or the nonlinear parameter without calibration of the air-coupled receiver and removes restrictions on the selection of reference samples.

Optimal Design of Annular Phased Array Transducers for Material Nonlinearity Determination in Pulse-Echo Ultrasonic Testing.

Nonlinear ultrasound has been proven to be a useful nondestructive testing tool for micro-damage inspection of materials and structures operating in harsh environment. When measuring the nonlinear second harmonic wave in a solid specimen in the pulse-echo (PE) testing mode, the stress-free boundary characteristics brings the received second harmonic component close to zero. Therefore, the PE method has never been employed to measure the so-called "nonlinear parameter (ß)", which is used to quantify the degree of micro-damage. When there are stress-free boundaries, a focused beam is known to improve the PE reception of the second harmonic wave, so phased-array (PA) transducers can be used to generate the focused beam. For the practical application of PE nonlinear ultrasonic testing, however, it is necessary to develop a new type of PA transducer that is completely different from conventional ones. In this paper, we propose a new annular PA transducer capable of measuring ß with improved second harmonic reception in the PE mode. Basically, the annular PA transducer (APAT) consists of four external ring transmitters and an internal disk receiver at the center. The focused beam properties of the transducers are analyzed using a nonlinear sound beam model which incorporates the effects of beam diffraction, material attenuation, and boundary reflection. The optimal design of the APAT is performed in terms of the maximum second harmonic reception and the total correction close to one, and the results are presented in detail.

Application of Fresnel Zone Plate Focused Beam to Optimized Sensor Design for Pulse-Echo Harmonic Generation Measurements.

In nonlinear acoustic measurements involving reflection from the stress-free boundary, the pulse-echo method could not be used because such a boundary is known to destructively change the second harmonic generation (SHG) process. The use of a focusing acoustic beam, however, can improve SHG after reflection from the specimen boundary, and nonlinear pulse-echo methods can be implemented as a practical means of measuring the acoustic nonlinear parameter (ß) of solid specimens. This paper investigates the optimal sensor design for pulse-echo SHG and ß measurements using Fresnel zone plate (FZP) focused beams. The conceptual design of a sensor configuration uses separate transmission and reception, where a broadband receiver is located at the center and a four-element FZP transmitter is positioned outside the receiver to create a focused beam at the specified position in a solid sample. Comprehensive simulations are performed for focused beam fields analysis and to determine the optimal sensor design using various combinations of focal length, receiver size and frequency. It is shown that the optimally designed sensors for 1 cm thick aluminum can produce the second harmonic amplitude and the uncorrected nonlinear parameter corresponding to the through-transmission method. The sensitivity of the optimal sensors to the changes in the designed sound velocity is analyzed and compared between the odd- and even-type FZPs.

Acoustic nonlinearity parameter measurements in a pulse-echo setup with the stress-free reflection boundary.

This paper describes the acoustic nonlinearity parameter (ß) determination for fluids using a pulse-echo method with the stress-free boundary. A newly derived ß formula requires the measurement of the fundamental and second harmonic displacements with appropriate corrections for attenuation, diffraction, and boundary reflection. Measurements are composed of two steps: receiver calibration and harmonic generation. The ß values calculated for water at several distances between the planar transducer and the water-air interface are in good agreement with literature, providing a validation for the method.

Calibration of focused ultrasonic transducers and absolute measurements of fluid nonlinearity with diffraction and attenuation corrections.

This paper presents analytical and experimental techniques for absolute determination of the acoustic nonlinearity parameter (ß) in fluids using focused transducers. When focused transducers are used for ß measurements, the geometrical and mechanical calibrations are generally required for accurate determination of the receiver transfer function from which the absolute pressure can be calculated. The fundamental and second harmonic wave amplitudes in harmonic generation measurements should be modified to account for beam diffraction and material absorption. All these issues are resolved in this study and the proposed technique is validated through the ß measurement in water. An experimental method is developed to determine the effective radius and focal length of focused transducers. A simplified self-reciprocity calibration procedure for a broadband focused receiver is described. The diffraction and attenuation corrections for the fundamental and second harmonic waves are explicitly derived using the multi-Gaussian beam model, and the effects on the ß determination are discussed. When the diffraction and attenuation corrections are all properly made, the measurement of ß over a large range of propagation distances is possible with errors less than 8%.

Receiver calibration and the nonlinearity parameter measurement of thick solid samples with diffraction and attenuation corrections.

This paper presents analytical and experimental techniques for accurate determination of the nonlinearity parameter (ß) in thick solid samples. When piezoelectric transducers are used for ß measurements, the receiver calibration is required to determine the transfer function from which the absolute displacement can be calculated. The measured fundamental and second harmonic displacement amplitudes should be modified to account for beam diffraction and material absorption. All these issues are addressed in this study and the proposed technique is validated through the ß measurements of thick solid samples. A simplified self-reciprocity calibration procedure for a broadband receiver is described. The diffraction and attenuation corrections for the fundamental and second harmonics are explicitly derived. Aluminum alloy samples in five different thicknesses (4, 6, 8, 10, 12cm) are prepared and ß measurements are made using the finite amplitude, through-transmission method. The effects of diffraction and attenuation corrections on ß measurements are systematically investigated. When diffraction and attenuation corrections are all properly made, the variation of ß between different thickness samples is found to be less than 3.2%.

Development of explicit diffraction corrections for absolute measurements of acoustic nonlinearity parameters in the quasilinear regime.

In absolute measurements of acoustic nonlinearity parameters, amplitudes of harmonics must be corrected for diffraction effects. In this study, we develop explicit multi-Gaussian beam (MGB) model-based diffraction corrections for the first three harmonics in weakly nonlinear, axisymmetric sound beams. The effects of making diffraction corrections on nonlinearity parameter estimation are investigated by defining "total diffraction correction (TDC)". The results demonstrate that TDC cannot be neglected even for harmonic generation experiments in the nearfield region.