Acoustic field visualisation using local absorption of ultrasound and thermochromic liquid crystals.

Acoustic field and vibration visualisation is important in a wide range of applications. Laser vibrometry is often used for such visualisation, however, the equipment has a high cost and requires significant user expertise, and the method can be slow, as it requires scanning point by point. Here we suggest a different approach to visualisation of acoustic fields in the kHz - MHz range, using paint-on or removable film sensors, which produce a direct visual map of ultrasound displacement. The sensors are based on a film containing thermochromic liquid crystals (TLC), along with a backing/underlay layer which improves absorption of ultrasound. The absorption generates heat, which can be seen by a change in colour of the TLC film. A removable sensor is used to visualise the resonant modes of an air-coupled flexural transducer operated from 410 kHz to 7.23 MHz, and to visualise 40 kHz standing waves in a Perspex plate. The thermal basis of the visualisation is confirmed using thermal imaging. The speed and cost of visualisation makes the new sensor attractive for use in condition monitoring, for fast assessment of transducer quality, or for analysis of acoustic field distribution in power ultrasonic systems.

The investigation of guided wave propagation around a pipe bend using an analytical modeling approach.

Guided wave inspection has the advantage of providing full volumetric coverage of tens of meters of pipe from a single test location. However, guided wave behavior is complex and there are many factors to consider such as the numerous possible vibrational modes and multiple reflections. The guided wave inspection technique is potentially valuable for pipelines that cannot be inspected with internal "pigs." However, in situations such as this, there are often bends in the pipe and the presence of the bend is known to distort the received signals. In order to address this issue, a study has been carried out that uses a combination of finite element analysis and experimentation to understand the behavior of guided waves in pipe bends. In addition to this, an analytical modeling methodology is put forward that uses basic information from finite element models of pipe bends to create a computationally fast solution to a potentially infinite number of scenarios. The analytical model can be used to both predict the effects of pipe bends on a range of signals and undo the distortion caused by pipe bends. Examples of this are given and compared to finite element results for flaws beyond pipe bends.

Rapid manufacture of monolithic micro-actuated forceps inspired by echinoderm pedicellariae.

The concept of biomimetics and bioinspiration has been used to enhance the function of materials and devices in fields ranging from healthcare to renewable energy. By developing advanced design and manufacturing processes, researchers are rapidly accelerating their ability to mimic natural systems. In this paper we show how micro-actuated forceps inspired by echinoderm pedicellarie have been produced using the rapid manufacturing technology of micro-stereolithography. The manufactured monolithic devices are composed of sets of jaws on the surface of thin polymer resin membranes, which serve as musculature for the jaws. The membranes are suspended above a pneumatic chamber with the jaws opened and closed through pneumatic pressure changes exerted by a simple syringe. The forceps can be used for tasks such as grasping of microparticles. Furthermore, when an object is placed in the centre of the membrane, the membrane flexes and the jaws of the device close and grasp the object in a responsive manner. When uncured liquid photopolymer is used to actuate the devices hydraulically instead of pneumatically, the devices exhibit self-healing behaviour, sealing the damaged regions and maintaining hydraulic integrity. The manufactured devices present exciting possibilities in fields such as micromanipulation and micro-robotics for healthcare.

Fabrication and analysis of cylindrical resin AFM microcantilevers.

In this paper a new method of fabricating cylindrical resin microcantilevers using the Direct Digital Manufacturing (DDM) technique of Micro-stereolithography (MSL) is described. The method is rapid and commercially viable, allowing the fabrication of atomic force microscope (AFM) cantilevers which exhibit much larger spring constants than those currently commercial available. This allows for experimentation in a force regime orders of magnitude higher than currently possible using the AFM. This makes these cantilevers ideally suited for AFM-based depth sensing indentation. Due to their geometry, the assumptions used in the standard Euler-Bernoulli beam theory usually used to analyse AFM cantilevers may no longer be valid. Therefore approximate analytical solutions based on Timoshenko beam theory have been derived for the stiffness and resonant frequency of these cantilevers. Prototypes of the cantilevers have been fabricated and tested. Results show good agreement between experiment and theory.

Structural health monitoring using polymer-based capacitive micromachined ultrasonic transducers (CMUTs).

Transducers based on a capacitive micromachined ultrasonic transducer (CMUT) design have been fabricated using a rapid prototyping technique. This results in a device that is constructed principally from polymers, in a process which is simple and inexpensive. The resultant devices can be attached to the surfaces of solids. Their peak sensitivity is in the 80-100 kHz range, making them ideal for applications such as acoustic emission and structural health monitoring. Good low frequency sensitivity leads to applications in vibration monitoring.

Micro-stereolithography as a transducer design method.

This paper investigates the use of micro-stereolithography, a rapid prototyping technique, in the manufacture of transducers. It is illustrated for the production of electromagnetic acoustic transducer (EMATs) coils in both meander-line and spiral configurations. A synthetic aperture focussing technique (SAFT) has been applied to the ultrasonic signals from these devices to reconstruct images in metallic objects.

Acoustic fields of nonplanar radiators.

A theoretical approach is described which predicts the fields of acoustic radiators with a predefined surface topography. This is achieved by dividing the surface of the source into small elements, each of which is oriented parallel to the tangent to the surface at that point. The result is an improved modeling performance, in that it is more efficient and requires far fewer elements compared to other numerical approaches using parallel elements. Theoretical predictions are compared to experimental results from curved electrostatic radiators, to demonstrate that the approach has promise.

The radiated fields of focussing air-coupled ultrasonic phased arrays.

This paper presents an investigation into the fields radiated into air by ultrasonic phased arrays under transient excitation. In particular, it includes a theoretical prediction of spatial variations in amplitude throughout the both the near-field and far-field of such arrays. The approach has been used to predict the result of phasing to produce a focus in air, which can be seen to be particularly effective in the near-field of the array. Interesting features are observed, which are then described in terms of the performance of both individual elements and the resulting array. It is shown how some elements of design can be used to improve performance in focussing. The predictions are compared to the results of experiments in air using electrostatic arrays, where good focussing could be achieved provided the appropriate design principles were followed. The approach has been developed specifically for use in air, but the results would also hold for modelling in certain medical arrays where a focussing requirement might be needed close to the array itself.

Modelling of the radiated field from multi-element capacitive micromachined ultrasonic transducers.

This paper presents results from a theoretical model of the ultrasonic fields radiated by a 3x3 assembly of capacitive micromachined ultrasonic transducer (cMUT) sources on the same silicon substrate. These predictions have, for the first time, been compared directly to the fields measured experimentally using a scanned miniature detector. This work indicates that there is minimal cross-coupling between source elements, and demonstrates that it is possible to predict successfully the field characteristics of various geometries of such cMUT elements, with a view to the development of future imaging systems.

Imaging using air-coupled polymer-membrane capacitive ultrasonic arrays.

Polymer-membrane capacitive ultrasonic linear and 2-D arrays have been fabricated for use in air-coupled imaging. By using arrays as receivers, there is a possibility of much faster imaging as the need for physically moving the receiver to scan a sample can be replaced by electronic multiplexing. In order to utilise this, a through-thickness air-coupled image of a composite plate has been made using a 2-D array as a receiver and a comparatively large planar source in air. This was made possible by the use of a chirp drive signal and cross-correlation on the measured waveform. Larger 2-D arrays with an increased number of elements have been simulated using a small scanned single receiver, and excellent imaging potential demonstrated. In addition two array receivers have been used in conjunction with two methods of post-processing, SAFT and ellipse crossing, to locate objects accurately.

Gas jets as ultrasonic waveguides.

The study of the propagation of ultrasound within a gas jet is extended to obtain waveguide effects, where the jet collimates the ultrasonic beam from a transducer within the flow. Two methods have been investigated to achieve this--cooling the gas within the air jet, and using a different gas whose acoustic velocity is lower than air. Cooling an air jet to a temperature less than that of the surrounding air produced a noticeable waveguide effect. In addition, studies have been carried out using other selected gases, such as carbon dioxide (CO2) with a lower acoustic velocity than air, and helium (He) with a higher value. The former gas enhanced confinement of the ultrasonic beam, whereas the latter caused divergence. An ideal solution was found to be a CO2/air mixture, which produced a well-collimated sound field along the axis, while limiting the excess attenuation of pure CO2 gas jets. The effectiveness of the waveguide using mixed gas jets in producing images in air-coupled testing of solids is demonstrated.

A conical air-coupled capacitance transducer for surface imaging.

This paper describes the construction and operation of an air-coupled capacitance transducer with a conical backplate. This was designed to produce a focal region over an extended distance along the transducer axis. Measurements were performed to examine both the frequency response of the transducer in pulse-echo mode, and the lateral resolution for imaging purposes. The radiated field was measured and compared to theory, and the extent of the focal region determined. Images of surface topography are presented, to illustrate the range of application of the transducer.

Gas jet as a waveguide for air-coupled ultrasound.

The directional characteristics of an ultrasonic signal have been studied during propagation within an axial gas jet. The effects of nozzle shape, nozzle diameter, and variations in jet velocity, temperature and gas composition have been investigated. At high flow velocities of an air jet, divergence of the ultrasonic beam was observed. This was attributed to the effects of refraction, caused by increased acoustic velocities in the direction of the flow. An effective waveguide was also demonstrated by cooling the air jet to below ambient temperatures, so that the acoustic velocity in the air jet was lower than that in the surrounding atmosphere. This could also be achieved by using carbon dioxide mixed with air, whereas the use of helium led to increased divergence. The result is likely to be of use in air-coupled ultrasonic materials inspection.

The characterization of capacitive micromachined ultrasonic transducers in air.

Surface micromachined, capacitive ultrasonic transducers have been fabricated using a low thermal budget, CMOS-compatible process. They exhibit interesting properties for transduction in air at frequencies in excess of 1 MHz, when driven from a standard ultrasonic voltage source. Experiments are described using 1 mm square devices in air, operating in both pitch-catch and pulse-echo modes. The dependence on d.c. bias voltage is examined, together with calibration measurements using 1/8 in. microphones. The radiated beam profile, and the farfield directivity pattern, have been measured for both broad bandwidth and one-burst excitation, using a scanned miniature receiver. A 16 element square array is also presented, which has been used to measure the beam cross-sections from a focussed source.

The use of broadband acoustic transducers and pulse-compression techniques for air-coupled ultrasonic imaging.

A pulse-compression technique has been applied to air-coupled testing of solid materials. Capacitance transducers were used to generate wide bandwidth swept-frequency (chirp) signals in air, which were then used to measure and image solid samples in through transmission. The results demonstrate that such signal processing techniques lead to an improvement in the signal to noise ratio and timing accuracy for air-coupled testing. Measurements of thickness and spectroscopic experiments are presented. Images of defects in a wide range of materials, including metals and carbon-fibre composites have also been obtained. This combination of capacitive transducers with pulse-compression techniques is shown to be a powerful tool for non-contact air-coupled ultrasonic measurements.

The use of air-coupled ultrasound to test paper.

Capacitance transducers containing a thin polymer membrane have been used to transmit ultrasonic signals with frequencies in excess of 1 MHz through various paper products such as paper and cardboard. At normal incidence, a resonance was visible in thicker samples, the frequency of which could be correlated to parameters such as the thickness of the paper sample and the moisture content. It has also been demonstrated that images can be obtained of changes in structure across paper and card samples.

Novel, wide bandwidth, micromachined ultrasonic transducers.

Surface micromachined, capacitive ultrasonic transducers have been fabricated using a low thermal budget, CMOS-compatible process. This process allows inherent control of parameters such as membrane size and thickness, cavity size and the intrinsic stress in the membrane to be achieved. Devices fabricated using this process exhibit interesting properties for transduction in air at frequencies in excess of 1 MHz when driven from a standard ultrasonic voltage source. Experiments have been performed with devices containing silicon nitride membranes of variable thicknesses over a 2 microm thick air cavity and with device dimensions of up to 5 mm square. This is much larger than has been reported for a device with a single membrane. Calibration measurements using 1/8 inch microphones in air, and miniature PVDF hyrdophones in water, have been performed. The dependence on d.c. bias voltage is examined, involving static membrane deflection measurements and received peak voltages. Pulse-echo and pitch-catch mode operation have been achieved. Interferometric measurements of membrane displacement have been performed in air to illustrate the membrane deflection characteristics. Operation in liquids is also discussed.

Neural network correction of ultrasonic C-scan images.

A neural network-based approach to the correction of C-scan images is presented. This allows the effects of a finite ultrasonic beam diameter in an immersion experiment to be considered, by training the network on a series of defects of known characteristics. The result is an image which is a better representation of the actual defect.