Inspection of thick welded joints using laser-ultrasonic SAFT.

The detection of defects in thick butt joints in the early phase of multi-pass arc welding would be very valuable to reduce cost and time in the necessity of reworking. As a non-contact method, the laser-ultrasonic technique (LUT) has the potential for the automated inspection of welds, ultimately online during manufacturing. In this study, testing has been carried out using LUT combined with the synthetic aperture focusing technique (SAFT) on 25 and 50mm thick butt welded joints of steel both completed and partially welded. EDM slits of 2 or 3mm height were inserted at different depths in the multi-pass welding process to simulate a lack of fusion. Line scans transverse to the weld are performed with the generation and detection laser spots superimposed directly on the surface of the weld bead. A CCD line camera is used to simultaneously acquire the surface profile for correction in the SAFT processing. All artificial defects but also real defects are visualized in the investigated thick butt weld specimens, either completed or partially welded after a given number of passes. The results obtained clearly show the potential of using the LUT with SAFT for the automated inspection of arc welds or hybrid laser-arc welds during manufacturing.

On-line measurement of texture, thickness and plastic strain ratio using laser-ultrasound resonance spectroscopy.

Laser-ultrasound resonance spectroscopy, a non-contact ultrasonic technique, was used to determine reliably and rapidly the crystallographic texture, the average plastic strain ratio, and the thickness of sheet metal on the production line. As with laser-ultrasonics, a short laser pulse is used to generate a wide-band pulse of ultrasound and a laser interferometer is used for its detection. In this paper, a large number of echoes are collected and analyzed together using Fourier techniques to measure the natural resonance frequencies in the thickness of the sheet. One longitudinal and two shear resonance frequencies were measured together with their harmonics. From these frequencies, two crystallographic orientation distribution coefficients, W(400) and W(420), are obtained, as well as a highly accurate measurement of the sheet thickness that is corrected for changes in ultrasonic velocity caused by texture variations. Using these coefficients, the average and in-plane twofold and fourfold variations of the plastic strain ratio, respectively r delta(2)r, and delta(4)r, can be evaluated. These parameters are indications of the formability of metals sheets, which is of industrial interest. Measurements on 1 mm thick, low carbon steel sheets have shown the following measurement accuracies: r to within +/-0.08, delta(2)r, and delta(4)r to within +/-0.1, and thickness to better than +/-1 microm. On-line tests at LTV Steel Company showed that the sensitivity of the apparatus is sufficient to detect systematic variations in texture along the length of similar production coils and that the on-line repeatability for r was of order +/-0.02.

Performance of laser-ultrasonic F-SAFT imaging.

The resolution and signal-to-noise ratio of laser-ultrasonics to detect small and buried defects can be greatly enhanced by using the synthetic aperture focusing technique (SAFT). Originally developed in the time domain, SAFT can also be implemented in the frequency domain (F-SAFT) using the angular spectrum approach for a significant reduction in processing time. In this paper, an F-SAFT based data processing method especially adapted to laser-ultrasonic data is presented. This method allows for further significant improvements towards laser-ultrasonic imaging of small defects. It includes temporal deconvolution of the waveform data, control for an optimal aperture and frequency bandwidth as well as spatial interpolation of the subsurface images. All the above operations are well adapted to the frequency domain calculations and embedded in the F-SAFT data processing. Also, the aperture control and spatial interpolation allow a reduction of sampling requirements to further decrease both inspection and processing times. The above improvements are illustrated using laser-ultrasonic data taken from an aluminum sample with flat-bottom holes.

Improved resolution and signal-to-noise ratio in laser-ultrasonics by SAFT processing.

Laser-ultrasonics is an emerging nondestructive technique using lasers for the generation and detection of ultrasound which presents numerous advantages for industrial inspection. In this paper, the problem of detection by laser-ultrasonics of small defects within a material is addressed. Experimental results obtained with laser-ultrasonics are processed using the Synthetic Aperture Focusing Technique (SAFT), yielding improved flaw detectability and spatial resolution. Experiments have been performed on an aluminum sample with a contoured back surface and two flat-bottom holes. Practical interest of coupling SAFT to laser-ultrasonics is also discussed.

Magnitude and phase photoacoustic spectra of chrysotile asbestos, a powdered sample.

Magnitude and phase photoacoustic spectra of a powdered sample made of chrysotile asbestos have been recorded with a low resolution grating spectrometer at ~16 Hz. A good reproduction of the true absorption spectra is obtained from the recording of the phase variation. The optical, thermal, and acoustical effects occurring within this heterogeneous sample are discussed, and a qualitative explanation of the observations is given.

Accurate laser wavelength measurement with a precision two-beam scanning Michelson interferometer.

This paper gives the details of a precision two-beam scanning Michelson interferometer, designed and perfected for accurate comparison of an unknown laser wavelength and the precisely calibrated wavelength of a reference laser. An iodine Lamb-dip stabilized He-Ne 633-nm laser (calibrated with respect to a Kr standard) is used as the reference. The design incorporates features to minimize instrumental errors and the effect of fringe shifts caused by diffraction (in the IR). It is applied to accurate measurements of a stable CO(2) laser wavelength tuned to the centers of its various transitions. Measurements are done by simultaneous fringe counting and relative fringe-phase comparison at the two wavelengths using on-line data storage and processing with an electronic digital computer. The accuracy in the 10-microm region is several parts in 10(9) and is limited by correction for diffraction fringe shifts. Because of its low-Q and broadband operating characteristics, it can be applied to rapid accurate laser wavelength measurements over the entire wavelength range permitted by its transmitting optics. In the visible range where the diffraction correction is small, the interferometer can be used to perform measurements to within several parts in 10(11). The paper gives theoretical derivation of various diffraction corrections, the design and construction of the interferometer, the alignment procedures, detailed analysis of various error sources, and data processing. It also gives the details of a previously reported accurate measurement of the speed of light using the measured wavelength of the CO(2) R(14) line and its known frequency.

Design of a compact cw chemical HF/DF laser using a microwave discharge.

A compact cw chemical HF/DF laser is described. The laser system consists of a microwave discharge using a surfatron to dissociate SF6 molecules mixed with He, a reaction chamber engineered to provide a fast mixing of reacting atoms and molecules, and an optical resonator which includes a concave mirror and a blazed grating for line selection, both mounted on a rigid Invar frame. The laser oscillates on a single line single TEM00 mode over many P transitions of HF and DF with a typical intensity fluctuation of 5% and a frequency jitter of about 30 MHz.