Full-range stress-strain curve estimation of aluminum alloys using machine learning-aided ultrasound.

Full-range stress-strain (SS) curves are crucial in understanding mechanical properties of a material such as the yield strength, ultimate tensile strength, and elongation. In this study, a full-range SS-curve was nondestructively estimated by applying machine learning to the ultrasonic amplitude-scan signal propagated through the material. The performance of the developed technique was validated using five-hundred aluminum alloy specimens with a wide spectrum of mechanical properties. The analyses of various ultrasonic properties, including nonlinearity and attenuation, with respect to the elements in the SS curves revealed how ultrasonics can be used to predict the SS curves without conventional destructive tensile testing. The proposed technique has significant potential for new applications in the fields of materials science and engineering, such as inline SS curve estimation during manufacturing.

Microstructural Characterization of Additively Manufactured Metal Components Using Linear and Nonlinear Ultrasonic Techniques.

Metal additive manufacturing (AM) is an innovative manufacturing technology that uses a high-power laser for the layer-by-layer production of metal components. Despite many achievements in the field of AM, few studies have focused on the nondestructive characterization of microstructures, such as grain size and porosity. In this study, various microstructures of additively manufactured metal components were characterized non-destructively using linear/nonlinear ultrasonic techniques. The contributions of this study are as follows: (1) presenting correlation analyses of various microstructures (grain size and texture, lack of fusion, and porosity) and ultrasonic properties (ultrasonic velocity, attenuation, and nonlinearity parameters), (2) development of nondestructive microstructural characterization techniques for additively manufactured components; and (3) exploring the potential for the online monitoring of AM processes owing to the nondestructive nature of the proposed technique. The performance of the proposed technique was validated using additively manufactured samples under varying laser beam speed conditions. The characteristics of the target microstructures characterized using the proposed technique were consistent with the results obtained using destructive optical microscopy and electron back-scattered diffraction methods.

Experimental Verification of Contact Acoustic Nonlinearity at Rough Contact Interfaces.

When a longitudinal wave passes through a contact interface, second harmonic components are generated due to contact acoustic nonlinearity (CAN). The magnitude of the generated second harmonic is related to the contact state of the interface, of which a model has been developed using linear and nonlinear interfacial stiffness. However, this model has not been sufficiently verified experimentally for the case where the interface has a rough surface. The present study verifies this model through experiments using rough interfaces. To do this, four sets of specimens with different interface roughness values (Ra = 0.179 to 4.524 µm) were tested; one set consists of two Al6061-T6 blocks facing each other. The second harmonic component of the transmitted signal was analyzed while pressing on both sides of the specimen set to change the contact state of the interface. The experimental results showed good agreement with the theoretical prediction on the rough interface. The magnitude of the second harmonic was maximized at a specific contact pressure. As the roughness of the contact surface increased, the second harmonic was maximized at a higher contact pressure. The location of this maximal point was consistent between experiments and theory. In this study, an FEM simulation was conducted in parallel and showed good agreement with the theoretical results. Thus, the developed FEM model allows parametric studies on various states of contact interfaces.

Compensation of a Second Harmonic Wave Included in an Incident Ultrasonic Wave for the Precise Measurement of the Acoustic Nonlinearity Parameter.

The incident second harmonic wave is a problematic issue for the precise measurement of the acoustic nonlinearity parameter. This paper proposes a compensation method to remove the effect of the incident second harmonic component in the measurement of the absolute acoustic nonlinearity parameter using the calibration method. For this, the second harmonic component detected by the receiving transducer is considered as the sum of the component due to material nonlinearity and the component included in the incident signal and a numerical calculation model is developed as a function of the propagation distance. In the model, the factors related to the material nonlinear parameter and the magnitude of the incident second harmonic component are unknown and these are determined by finding a value that best matches the experimental data according to the change in the propagation distance; compensation for the incident second harmonic component is then achieved. The case where the phase of the second harmonic wave due to material nonlinearity is opposite to that of the fundamental wave is also considered. To verify the validity of the proposed method, fused silica and aluminum alloy Al6061-T6 specimens with different thicknesses corresponding to the propagation distance are tested. The experimental results show that the nonlinear parameters changed significantly according to the propagation distance before compensation but were very stable after compensation. Additionally, the average values of the nonlinear parameter are 11.04 in the fused silica, which is within the literature value range (10.1 to 12.4), and that for the Al6061-T6 is 6.59, which is close to the literature value range (4.5 to 6.12).

Rapid Molecular Diagnostic Sensor Based on Ball-Lensed Optical Fibers.

Given the fatal health conditions caused by emerging infectious pathogens, such as severe acute respiratory syndrome coronavirus 2, their rapid diagnosis is required for preventing secondary infections and guiding correct treatments. Although various molecular diagnostic methods based on nucleic acid amplification have been suggested as gold standards for identifying different species, these methods are not suitable for the rapid diagnosis of pathogens owing to their long result acquisition times and complexity. In this study, we developed a rapid bio-optical sensor that uses a ball-lensed optical fiber (BLOF) probe and an automatic analysis platform to precisely diagnose infectious pathogens. The BLOF probe is easy to align and has a high optical sensing sensitivity (1.5-fold) and a large detection range (1.2-fold) for an automatic optical sensing system. Automatic signal processing of up to 250 copies/reaction of DNA of Q-fever-causing Coxiella burnetii was achieved within 8 min. The clinical utility of this system was demonstrated with 18 clinical specimens (9 Q-fever and 9 other febrile disease samples) by measuring the resonant wavelength shift of positive or negative samples for Coxiella burnetii DNA. The results from the system revealed the stable and automatic optical signal measurement of DNA with 100% accuracy. We envision that this BLOF probe-based sensor would be a practical tool for the rapid, simple, and sensitive diagnosis of emerging infectious pathogens.

Ultrasonic nonlinearity parameter in uniaxial stress condition.

The ultrasonic nonlinearity parameter derived for one-dimensional propagation of a longitudinal wave in an isotropic material has been considered useful in the evaluation of material degradation. To demonstrate this, many researchers have reported on the correlation with the yield strength obtained from a tensile test. However, there is an essential issue with this procedure - which is that the ultrasonic nonlinearity parameter is derived in a state where the lateral strain is restrained, whereas the tensile test to measure the yield strength is carried out under uniaxial stress conditions, where lateral deformation is free. In this study, to address this issue, the authors have defined the ultrasonic nonlinearity parameter under uniaxial stress conditions which were the same as the tensile test, and showed that the correlation with the yield strength was higher than the currently used ultrasonic nonlinearity parameter. To verify the validity of the proposed ultrasonic nonlinearity parameter, experiments were carried out for Al6061-T6 alloy specimens heat-treated with different aging times. Results showed that the proposed ultrasonic nonlinearity parameter exhibited a much higher correlation with yield strength than the currently used nonlinearity parameter.

Dependence of nonlinear ultrasonic characteristic on second-phase precipitation in heat-treated Al 6061-T6 alloy.

It is well known that nonlinear ultrasound is sensitive to certain microstructural features in materials such as dislocations and precipitates. This paper investigates the dependence of the nonlinear ultrasonic characteristic on MgnSim precipitation in heat-treated Al 6061-T6 alloy specimens. The specimens were heat-treated at a constant temperature of 220°C for different exposure times up to 6000min. The accuracy of the ultrasonic measurement setup that determines the absolute ultrasonic nonlinearity parameter ßu was first validated. The nonlinearity parameter and the yield strength were measured for each of the artificially aged specimens. The experimental results show fluctuations in the nonlinearity parameter and yield strength over the aging time, but with an interesting correlation between the nonlinearity parameter and the yield strength over the aging time. Microstructural observations confirmed that those fluctuations are due to the formation and evolution of precipitates that occurs in a unique precipitation sequence in this alloy. These results suggest that the nonlinear ultrasonic measurement can be useful for monitoring second phase precipitation and related mechanical properties in the Al 6061-T6 alloy.

A method to estimate the absolute ultrasonic nonlinearity parameter from relative measurements.

The ultrasonic nonlinearity parameter (ß) is determined from the particle displacement amplitudes of the fundamental and second-order harmonic components in an ultrasonic wave propagated through a material. This parameter is generally referred to as the absolute parameter. However, measuring the second harmonic component is especially difficult because its amplitude is usually much smaller than those of signals in typical ultrasonic measurements. For this reason, most studies use the relative parameter determined using the measured electric signal amplitudes of the fundamental and second harmonic ultrasonic waves. However, in many occasions, the absolute parameter is needed for a quantitative assessment of material degradation. This study proposes a method to estimate the absolute parameter from a measured relative parameter along with a proportionality constant between normalized absolute and relative parameters. This method is based on the observed fact that the ratio of between normalized relative and absolute parameters is identical after compensating proportionality constant. The method was experimentally validated for Al6061-T6 alloy specimens heat-treated for different aging times. The parameter determined through the proposed method were compared with the absolute parameters which were measured separately. The results show that these two parameters were close to each other within the measurement errors.

Nanotribological and wetting performance of hierarchical patterns.

Surface modification is a promising method to solve the tribological problems in microsystems. To modify the surface, we fabricated hierarchical patterns with different pitches of nano-scale features and different surface chemistries. Micro- and nano-patterns with similar geometrical configurations were also fabricated for comparison. The nano-tribological behavior of the patterns was investigated using an atomic force microscope at different relative humidity levels (5% to 80%) and applied normal loads (40 nN to 120 nN) under a constant sliding velocity. The results showed significant enhancement in the de-wetting and tribological performance of the hierarchical patterns compared with those of flat and micro- and nano-patterned surfaces. The PTFE-coated hierarchical patterns showed similar dynamic contact angles (advancing and receding) to those of the real lotus leaf. The influence of relative humidity on adhesion and friction behavior was found to be significant for all the tested surfaces. The tribological performance was improved as the pitch of the nano-scale geometry of the hierarchical pattern increased, even though the wetting property was not influenced significantly. A model was proposed based on the role of intermolecular force to explain the effect of the pitch of the hierarchical patterns on the adhesion and friction behavior. According to the model based on the molecular force, the contact between a ball and the patterned surface was a multi-asperity contact, contrary to the single-asperity contact predicted by the Johnson-Kendall-Roberts (JKR) and Maugis-Dugdale (MD) models. The strong intermolecular forces, which are activated in the confined spaces between the adjacent nano-pillars and the ball, contributed to the contact area and hence the adhesion and friction forces.

Relationship between second- and third-order acoustic nonlinear parameters in relative measurement.

The higher-order acoustic nonlinear parameters are considered effective damage indices in the field of nondestructive evaluation (NDE). They are defined by using the displacement amplitudes of the fundamental frequency and the harmonics, which are called the absolute nonlinear parameters. Generally, however, it is difficult to measure the very small displacement amplitudes of high-frequency harmonics. Therefore, the simplified parameters using the detected wave signal amplitudes, which are known as the relative nonlinear parameters, have been widely used, although their applications are limited to the relative comparison of before and after damage of a single material under consistent experimental circumstances. In this paper, in order to make clear the concept of relative parameter, we presented first that the relative ratio of the simplified parameters is identical to that of the absolute parameters when the detected signal amplitudes are linearly proportional to the actual displacement amplitudes with respect to the fundamental frequency and the harmonics. In addition, the new relationship between the relative ratio of simplified second-order parameter and the relative ratio of simplified third-order parameter was derived from the relationship between the absolute second- and third-order parameters. This new relationship was successfully verified based on experimental results obtained from Al 6061-T6 processed for different heat treatment times, where it was confirmed in advance that the PZT detection signal amplitudes at the fundamental frequency and its second- and third-order harmonics were linearly proportional to the displacement amplitudes.

In-line ultrasonic monitoring for sediments stuck on inner wall of a polyvinyl chloride pipe.

This research verified the applicability and effectiveness of the ultrasonic monitoring of sediments stuck on the inner wall of polyvinyl chloride (PVC) pipes. For identifying the transmittance of acoustic energy and the speed of sound in the PVC material, the pulse-echo ultrasonic testing was conducted for PVC sheets of different thicknesses. To simulate the solidified sediment, the hot melt adhesive (HMA) was covered on the inner wall of the PVC pipe in different heights. From the experiment, the speeds of sound in the PVC and the HMA materials were obtained as about 2258 and 2000 m/s, respectively. The thickness of the materials was calculated through the signal processing such as taking the absolute value and low pass filtering, the echo detection, and the measurement of the time of flight. The errors between actual and measured thicknesses of PVC sheets were below 5%. In the case of the substance stuck on the inner wall, the errors were below 2.5%. Since the pulse-echo ultrasonic inspection is available on the outer surface and its measurement accuracy was over 95%, it can be an efficient and effective in-service structural health monitoring for the sediment on the wall of PVC pipes.

In situ detection of laser-induced slip initiation on the silicon wafer surface.

We propose a real-time in situ method to detect slip initiation on the surface of silicon wafers during high-power laser beam irradiation. In this method, light is collected from the surface of a silicon wafer subjected to laser irradiation. When the slip is initiated, it strongly scatters the laser beam, allowing detection of the time of the slip initiation based on the resulting sudden increase in the scattering signal. To demonstrate the performance of this method, a silicon wafer specimen was illuminated by a near-infrared continuous-wave fiber laser beam (of wavelength 1070 nm) at four different laser powers, and the scattered light was detected. The scattering signal increased suddenly at the time of slip initiation. To confirm the occurrence of slip, the surface morphologies of the silicon specimens after laser irradiation were analyzed using an optical microscope; surface slips were observed only in the specimens for which the sudden increase in scattering had been detected. Thus, the proposed method is shown to be very effective for the real-time in situ detection of surface slip initiation induced by high-power laser beam irradiation on silicon wafers.

Imaging of contact acoustic nonlinearity using synthetic aperture technique.

The angle beam incidence and reflection technique for the evaluation of contact acoustic nonlinearity (CAN) at solid-solid contact interfaces (e.g., closed cracks) has recently been developed to overcome the disadvantage of accessing both the inner and outer surfaces of structures for attaching pulsing and receiving transducers in the through-transmission of normal incidence technique. This paper proposes a technique for B-mode imaging of CAN based on the above reflection technique, which uses the synthetic aperture focusing technique (SAFT) and short-time Fourier transform (STFT) to visualize the distribution of the CAN-induced second harmonic magnitude as well as the nonlinear parameter. In order to verify the usefulness of the proposed method, a solid-solid contact interface was tested and the change of the contact acoustic nonlinearity according to the increasing contact pressure was visualized in images of the second harmonic magnitude and the relative nonlinear parameter. The experimental results showed good agreement with the previously developed theory identifying the dependence of the scattered second harmonics on the contact pressure. This technique can be used for the detection and improvement of the sizing accuracy of closed cracks that are difficult to detect using the conventional linear ultrasonic technique.

Harmonic generation of an obliquely incident ultrasonic wave in solid-solid contact interfaces.

The conventional acoustic nonlinear technique to evaluate the contact acoustic nonlinearity (CAN) at solid-solid contact interfaces (e.g., closed cracks), which uses the through-transmission of normally incident bulk waves, is limited in that access to both the inner and outer surfaces of structures for attaching pulsing and receiving transducers is difficult. The angle beam incidence and reflection technique, where both the pulsing and receiving transducers are located on the same side of the target, may allow the above problem to be overcome. However, in the angle incidence technique, mode-conversion at the contact interfaces as well as the normal and tangential interface stiffness should be taken into account. Based on the linear and nonlinear contact stiffness, we propose a theoretical model for the reflection of an ultrasonic wave angularly incident on contact interfaces. In addition, the magnitude of the CAN-induced second harmonic wave in the reflected ultrasonic wave is predicted. Experimental results obtained for the contact interfaces of A16061-T6 alloy specimens at various loading pressures showed good agreement with theoretical predictions. Such agreement proves the validity of the suggested oblique incidence model.

Estimation of clamping force in high-tension bolts through ultrasonic velocity measurement.

The estimation of clamping force has been regarded as the main issue in the maintenance of high-tension bolts. This paper proposes a method which uses the dependency of ultrasonic velocity on stress based on the nonlinear elastic effect. The variation of ultrasonic velocity in the range of actual stress acting in the bolt is very small so that the precise measurement of ultrasonic velocity is needed. In this paper, we adopt a method to measure ultrasonic velocity, where the TOF (time of flight) of a tone-burst ultrasonic wave is precisely measured by using the phase detection technique. In order to verify the usefulness of the proposed method, two kinds of experiments are carried out. The first one measures ultrasonic velocity when the bolt is stressed by the tension tester, and from this, the exact axial force acting in the bolt can be determined. The results show good agreement with the expected linear relationship between ultrasonic velocity and axial stress. The second experiment measures ultrasonic velocity when the bolt is stressed by the torque wrench. The results show that ultrasonic velocity decreased as the torque increased, which is identical to the theoretically expected tendency. From these results, it can be said that the proposed method is adequate in evaluating clamping force in high-tension bolts.

Application of the laser generated focused-Lamb wave for non-contact imaging of defects in plate.

The laser generation method of focused-Lamb wave is expected to have high defect-detection ability with advantages of non-contact testing. In this method, the laser beam is illuminated on the surface of the object through an arrayed-arc slit, and then the energy of the generated Lamb wave is concentrated on the focus point of arc. This focusing effect enables the concentration of higher wave intensity on the focus with better S/N ratio of signal, and has better spatial resolution compared to the conventional line arrayed method. This paper describes a 2-D imaging system using this laser generated, focused-Lamb wave combined with its detection by the air-coupled transducer. This technique is fully non-contact so it can be easily applied for the automatic inspection. The effectiveness of the proposed method was verified by experiments on a 1-mm thick aluminum plate with artificial drill-hole defect with diameters of 1mm. The 2-D image of was constructed by scanning and the result showed that the location and size of defects were clearly detected.

A nondestructive method for estimation of the fracture toughness of CrMoV rotor steels based on ultrasonic nonlinearity.

The objective of this paper is to develop a nondestructive method for estimating the fracture toughness (K(IC)) of CrMoV steels used as the rotor material of steam turbines in power plants. To achieve this objective, a number of CrMoV steel samples were heat-treated, and the fracture appearance transition temperature (FATT) was determined as a function of aging time. Nonlinear ultrasonics was employed as the theoretical basis to explain the harmonic generation in a damaged material, and the nonlinearity parameter of the second harmonic wave was the experimental measure used to be correlated to the fracture toughness of the rotor steel. The nondestructive procedure for estimating the K(IC) consists of two steps. First, the correlations between the nonlinearity parameter and the FATT are sought. The FATT values are then used to estimate K(IC) using the K(IC) versus excess temperature (i.e., T-FATT) correlation that is available in the literature for CrMoV rotor steel.