Air-Coupled Ultrasonic Arrays for Assessment of Pipe Internal Geometry and Surface Condition.

This article explores what useful information can be retrieved from pipeline interiors using an air-coupled ultrasonic array. Experiments are performed using an array, custom array controller, and supporting electronics controlled by a Raspberry Pi 4, mounted on board a crawler robot. A 64-transducer 40-kHz array configuration is selected based on uniformity of imaging amplitude over the circumference of the pipe wall. Testing revealed joints between pipe sections could be imaged at high amplitude, and that angular displacement between sections produced a different response to a properly aligned joint, potentially enabling detection of faulty joints. The surface roughness of some pipes also provides enough backscatter to be imaged, which is useful for detecting regions of corrosion. It was also found that reflections from the pipe wall in the plane of the array allow imaging of the wall shape. This can indicate the presence of junctions, as well as detect ovality to within 1%. These in-plane wall reflections were also found to be a source of low-amplitude coherent noise throughout the imaging domain, which is of similar amplitude to small (< 10 mm) through-holes in the pipe wall.

Envelope correction for shear-longitudinal collinear wave mixing to extract absolute nonlinear acoustic parameters.

This paper addresses the effect of the excitation envelope on the generated nonlinear resonant signal (NRS) for collinear wave mixing of shear and longitudinal waves. The aim is to explore how the absolute material nonlinearity can be extracted accurately for any enveloped sinusoidal excitation signal. A finite difference time domain (FDTD) model was built to simulate the effect of input waveforms on the NRS. A change in the measured nonlinearity was seen as the input waveforms were changed from rectangular to Hanning windowed tone burst. The required waveform correction was derived theoretically and validated against the FDTD simulation. Experimental measurements were carried out for different waveforms at several input amplitudes, demonstrating its influence over the NRS. The theoretically derived correction factor, which is required to map the small NRS to the rectangular tone burst resonant amplitude, was validated experimentally. The correction was then used to extract one the fundamental Murnaghan constant (m). Comparatively, Hanning tone burst inputs showed lower variance in the extracted material property due to better control of the frequency bandwidth, relative to that of the transducers. This opens the opportunity to using Hanning windowed tone burst inputs reliably for the measurement of the absolute nonlinearity parameter and m through collinear shear-longitudinal wave mixing.

Dynamic patterning of microparticles with acoustic impulse control.

This paper describes the use of impulse control of an acoustic field to create complex and precise particle patterns and then dynamically manipulate them. We first demonstrate that the motion of a particle in an acoustic field depends on the applied impulse and three distinct regimes can be identified. The high impulse regime is the well established mode where particles travel to the force minima of an applied continuous acoustic field. In contrast acoustic field switching in the low impulse regime results in a force field experienced by the particle equal to the time weighted average of the constituent force fields. We demonstrate via simulation and experiment that operating in the low impulse regime facilitates an intuitive and modular route to forming complex patterns of particles. The intermediate impulse regime is shown to enable more localised manipulation of particles. In addition to patterning, we demonstrate a set of impulse control tools to clear away undesired particles to further increase the contrast of the pattern against background. We combine these tools to create high contrast patterns as well as moving and re-configuring them. These techniques have applications in areas such as tissue engineering where they will enable complex, high fidelity cell patterns.

Ultrasonic Nondestructive Characterization of Blockages and Defects in Underground Pipes.

This article explores the use of a 40-kHz air-coupled ultrasonic array in detecting and imaging blockages and defects in buried pipes with 17-26 wavelengths in diameter at short ranges (approximately 20-60 wavelengths). In particular, the imaging performance of arrays with different numbers of transducers is quantified and compared to establish how many are required for adequate performance. Even low numbers of transducers (<25) are capable of producing -6-dB contours of blockages that match reference images to within 95% by restricting the aperture to maintain element density. However, doing so also limits the resolving power, so arrays with more transducers ultimately image better by having great enough density even at larger apertures. Using <25 transducers also gives a poor contrast ratio of features above background noise (as low as 2), resulting in low tolerance for detection and producing unusable images in some cases. More robust performance is achieved with larger numbers of transducers, which achieves sufficient contrast. All images of planar objects feature a low-amplitude band due to interference between direct reflections and reflections via the pipe wall, which was verified by comparison to simulation. When tested in larger pipes in a deployment case, the low-amplitude band was notably larger but was found to decrease in size at longer ranges.

Strategies for guided acoustic wave inspection using mobile robots.

Continuous non-destructive monitoring of large-scale structures is extremely challenging with traditional manual inspections. In this paper, we explore possible strategies that a collection of inspection robots could adopt to address this challenge. We envision the continuous inspection of a plate performed by multiple robots or a single robot that combines measurements from multiple locations. The robots use guided ultrasonic waves to interrogate a localized region for defects such as cracking or corrosion. In the detection stage, the receiver operating characteristic defines a detection zone in which a defect is thought to be present. In the localization stage, further measurements are made to locate the defect within this zone to a certain accuracy. We then address the question of what additional measurements are needed to achieve a given level of performance in the presence of uncertainty in robot locations? We explore this problem with Monte Carlo simulations that reveal the compromise between number of robots and performance in terms of defect location accuracy. In an experimental validation example on an aluminium plate, we show that six measurements arranged in a pentagon with a central measurement point leads to localization errors of similar magnitude to the uncertainty in sensor location.

Optimal Extraction of Ultrasonic Scattering Features in Coarse Grained Materials.

Ultrasonic array imaging is used in nondestructive testing for the detection and characterization of defects. The scattering behavior of any feature can be described by a matrix of scattering coefficients, called the scattering matrix. This information is used for characterization, and contrary to image-based analysis, the scattering matrix allows the characterization of defects at the subwavelength scale. However, the defect scattering coefficients are, in practice, contaminated by other nearby scatterers or significant structural noise. In this context, an optimal procedure to extract scattering features from a selected region of interest in a beamformed image is here investigated. This work proposes two main strategies to isolate a target scatterer in order to recover exclusively the time responses of the desired scatterer. In this article, such strategies are implemented in delay-and-sum and frequency-wavenumber forms and optimized to maximize the extraction rate. An experimental case in a polycrystalline material shows that the suggested procedures provide a rich frequency spectrum of the scattering matrix and are readily suited to minimize the effects of surrounding scattering noise. In doing so, the ability to deploy imaging methods that rely on the scattering matrix is enabled.

Local scattering ultrasound imaging.

Ultrasonic imaging is a widely used tool for detection, localisation and characterisation of material inhomogeneities with important applications in many fields. This task is particularly challenging when imaging in a complex medium, where the ultrasonic wave is scattered by the material microstructure, preventing detection and characterisation of weak targets. Fundamentally, the maximum information that can be experimentally obtained from each material region consists of a set of reflected signals for different incident waves. However, these data are not directly accessible from the raw measurements, which represent a superposition of reflections from all scatterers in the medium. Here we show, that a complete set of transmitter-receiver data encodes sufficient information in order to achieve full spatio-temporal separation of transmitter-receiver data, corresponding to different local scattering areas. We show that access to the local scattering data can provide valuable benefits for many applications. More importantly, this technique enables fundamentally new approaches, exploiting the angular distribution of the scattering amplitude and phase of each local scattering region. Here we demonstrate how the local scattering directivity can be used to build the local scattering image, releasing the full potential and richness of the transmit-receive data. As a proof of concept, we demonstrate the detection of small inclusions in various highly scattering materials using numerical and experimental examples. The described principles are very general and can be applied to any research field where the phased array technology is employed.

Fusion of multi-view ultrasonic data for increased detection performance in non-destructive evaluation.

State-of-the-art ultrasonic non-destructive evaluation (NDE) uses an array to rapidly generate multiple, information-rich views at each test position on a safety-critical component. However, the information for detecting potential defects is dispersed across views, and a typical inspection may involve thousands of test positions. Interpretation requires painstaking analysis by a skilled operator. In this paper, various methods for fusing multi-view data are developed. Compared with any one single view, all methods are shown to yield significant performance gains, which may be related to the general and edge cases for NDE. In the general case, a defect is clearly detectable in at least one individual view, but the view(s) depends on the defect location and orientation. Here, the performance gain from data fusion is mainly the result of the selective use of information from the most appropriate view(s) and fusion provides a means to substantially reduce operator burden. The edge cases are defects that cannot be reliably detected in any one individual view without false alarms. Here, certain fusion methods are shown to enable detection with reduced false alarms. In this context, fusion allows NDE capability to be extended with potential implications for the design and operation of engineering assets.

Data Fusion of Multiview Ultrasonic Imaging for Characterization of Large Defects.

The multiview total focusing method (TFM) enables a region of interest within a specimen to be imaged using different ray paths and wave-mode combinations. For defects larger than the ultrasonic wavelength, different portions of the same defect may manifest in a number of views. For a crack, the tip diffraction response may be evident in certain views and the specular reflection in others. Accurate characterization of large defects requires the information in multiple views to be combined. In this work, three data fusion methodologies are presented: a simple sum over all views, a sum weighted according to the inverse of the noise in each view, and a matched filter approach. Four large defects are examined; one stress corrosion crack (SCC), two weld cracks, and a pair of slagline defects in a weld. The matched filter (matched to a small circular void) provided significant improvement over the best individual view. The data fusion process incorporates artifact removal, where nondefect artifact signals within each image view are identified and masked, using a single defect-free data set for training. The matched filter was able to accurately visualize the full 3-D extent of the four defects, allowing characterization via the decibel drop method. When compared to X-ray computed tomography and micrograph data in the case of the SCC, the matched filter fusion provided excellent agreement. Its performance was also superior to any individual view while providing a single fused image that is easier for an operator to interpret than a set of multiview images.

A model for multi-view ultrasonic array inspection of small two-dimensional defects.

The multi-view total focusing method (TFM) is an imaging algorithm for ultrasonic full matrix array data that exploits internal reflections and mode conversions in the inspected object to create multiple images, the views. Modelling the defect response in multi-view TFM is an essential first step in developing new detection and characterisation methods which exploit the information present in these views. This paper describes a ray-based forward model for small two-dimensional defects and compares its results against finite-element simulations and experimental data for the inspection of a side-drilled hole, a notch and a crack. A simpler version of this model, based on a single-frequency approximation, is derived and compared. A good agreement with the multi-frequency model and a speed-up of several orders of magnitude are achieved.

Experimental Quantification of Noise in Linear Ultrasonic Imaging.

An efficient procedure for experimental-based quantification of statistical distributions of both the random and microstructural speckle noise within an ultrasonic image is presented. This is of particular interest in the multiview total focusing method, which enables many images (views) of the same region to be obtained by utilizing alternative ray paths and mode conversions. For example, in an immersion configuration, 21 separate views of the same region of a sample can be formed by exploiting direct and skip paths. These views can be combined through some form of data fusion algorithm to improve defect detection and characterization performance. However, the noise level is different in different views and this should be accounted for in any data fusion algorithm. It is shown that by using only one set of experimental data from a single measurement location, rather than numerous independent locations, it is possible to obtain accurate noise parameters at an imaging level. This is achieved by accounting for the spatial variation in the noise parameters within the image, due to beam spread, directivity, and attenuation with a simple empirical correction. An important feature of the process is the suppression of image artifacts caused by signal responses from other ray paths with the use of image masking. This masking process incorporates knowledge of the expected autocorrelation length (ACL) of image speckle noise and high-amplitude cluster suppression. The expected ACL is determined via a simple ray-based forward model of a single point scatterer. Compared to the estimates obtained using multiple independent locations, the speckle noise parameters estimated from a single measurement location were within 0.4 dB.

Characterization of Nonlinear Ultrasonic Diffuse Energy Imaging.

Nonlinear ultrasonic diffuse energy imaging is a highly sensitive method for the measurement of elastic nonlinearity. While the underlying principles that govern the technique are understood, the precise behavior and sensitivity have not previously been quantified. This paper presents experimental, theoretical, and numerical modeling studies undertaken to characterize nonlinear diffuse energy imaging. The influence of incoherent noise, elastic nonlinearity, and instrumentation error are quantified. This paper enables the prediction of spatial sensitivity, aperture, and amplitude dependence of the measurement, all of which moves the technique toward industrial viability. Furthermore, while previous studies have focused on the detection of closed cracks, the ultimate aim for nonlinear ultrasonic imaging in application to material testing is the detection of damage precursors, which requires a sensitivity to weak classical nonlinearity. This paper identifies the experimental requirements necessary for this to be achieved, greatly expanding the potential applicability of nonlinear ultrasonic array imaging.

Numerical and experimental study of the nonlinear interaction between a shear wave and a frictional interface.

The nonlinear interaction of shear waves with a frictional interface are presented and modeled using simple Coulomb friction. Analytical and finite difference implementations are proposed with both in agreement and showing a unique trend in terms of the generated nonlinearity. A dimensionless parameter ξ is proposed to uniquely quantify the nonlinearity produced. The trends produced in the numerical study are then validated with good agreement experimentally. This is carried out loading an interface between two steel blocks and exciting this interface with different amplitude normal incidence shear waves. The experimental results are in good agreement with the numerical results, suggesting the simple friction model does a reasonable job of capturing the fundamental physics. The resulting approach offers a potential way to characterize a contacting interface; however, the difficulty in activating that interface may ultimately limit its applicability.

Investigation of capacitively coupled ultrasonic transducer system for nondestructive evaluation.

Capacitive coupling offers a simple solution to wirelessly probe ultrasonic transducers. This paper investigates the theory, feasibility, and optimization of such a capacitively coupled transducer system (CCTS) in the context of nondestructive evaluation (NDE) applications. The noncontact interface relies on an electric field formed between four metal plates-two plates are physically connected to the electrodes of a transducer, the other two are in a separate probing unit connected to the transmit/receive channel of the instrumentation. The complete system is modeled as an electric network with the measured impedance of a bonded piezoelectric ceramic disc representing a transducer attached to an arbitrary solid substrate. A transmission line model is developed which is a function of the physical parameters of the capacitively coupled system, such as the permittivity of the material between the plates, the size of the metal plates, and their relative positions. This model provides immediate prediction of electric input impedance, pulse-echo response, and the effect of plate misalignment. The model has been validated experimentally and has enabled optimization of the various parameters. It is shown that placing a tuning inductor and series resistor on the transmitting side of the circuit can significantly improve the system performance in terms of the signal-to-crosstalk ratio. Practically, bulk-wave CCTSs have been built and demonstrated for underwater and through-composite testing. It has been found that electrical conduction in the media between the plates limits their applications.

Chirp excitation of ultrasonic guided waves.

Most ultrasonic guided wave methods require tone burst excitations to achieve some degree of mode purity while maintaining temporal resolution. In addition, it is often desirable to acquire data using multiple frequencies, particularly during method development when the best frequency for a specific application is not known. However, this process is inconvenient and time-consuming, particularly if extensive signal averaging at each excitation frequency is required to achieve a satisfactory signal-to-noise ratio. Both acquisition time and data storage requirements may be prohibitive if responses from many narrowband tone burst excitations are measured. Here chirp excitations are utilized to address the need to both test at multiple frequencies and achieve a high signal-to-noise ratio to minimize acquisition time. A broadband chirp is used to acquire data at a wide range of frequencies, and deconvolution is applied to extract multiple narrowband responses. After optimizing the frequency and duration of the desired tone burst excitation, a long-time narrowband chirp is used as the actual excitation, and the desired tone burst response is similarly extracted during post-processing. Results are shown that demonstrate the efficacy of both broadband and narrowband chirp excitations.

Investigation of inductively coupled ultrasonic transducer system for NDE.

Inductive coupling offers a simple solution to wirelessly probe ultrasonic transducers. This paper investigates the theory and feasibility of such an inductively coupled transducer system in the context of nondestructive evaluation (NDE) applications. The noncontact interface is based on electromagnetic coupling between three coils; one of the coils is physically connected to the transducer, the other two are in a separate probing unit, where they are connected to the transmit and receive channels of the instrumentation. The complete system is modeled as a three-port network with the measured impedance of a bonded piezoelectric ceramic disc representing a sensor attached to an arbitrary solid substrate. The developed transmission line model is a function of the physical parameters of the electromagnetic system, such as the number of turns and diameter of each coil, and their separation. This model provides immediate predictions of electrical input impedance and pulse-echo response. The model has been validated experimentally and a sensitivity analysis of the input parameters performed. This has enabled optimization of the various parameters. Inductively coupled transducer systems have been built for both bulk and guided wave examples. By using chirped excitation and baseline subtraction, inspection distance of up to 700 mm is achieved in single-shot, guided-wave pulse-echo mode measurements with a 5 mm separation between the probing coils and transducer coil on an aluminum plate structure. In the bulk wave example, a delamination in an 8.9-mm-thick carbon fiber composite specimen is successfully identified from the changes in the arrival time of a reflected pulse.

The microbial habitability of weathered volcanic glass inferred from continuous sensing techniques.

Basaltic glasses (hyaloclastite) are a widespread habitat for life in volcanic environments, yet their interior physical conditions are poorly characterized. We investigated the characteristics of exposed weathered basaltic glass from a surface outcrop in Iceland, using microprobes capable of continuous sensing, to determine whether the physical conditions in the rock interior are hospitable to microbial life. The material provided thermal protection from freeze-thaw and rapid temperature fluctuations, similar to data reported for other rock types. Water activity experiments showed that at moisture contents less than 13% wet weight, the glass and its weathering product, palagonite, had a water activity below levels suitable for bacterial growth. In pore spaces, however, these higher moisture conditions might be maintained for many days after a precipitation event. Gas exchange between the rock interior and exterior was rapid (< 10 min) when the rocks were dry, but when saturated with water, equilibration took many hours. During this period, we demonstrated the potential for low oxygen conditions within the rock caused by respiratory stimulation of the heterotrophic community within. These conditions might exist within subglacial environments during the formation of the rocks or in micro-environments in the interior of exposed rocks. The experiments showed that microbial communities at the site studied here could potentially be active for 39% of the year, if the depth of the community within the outcrop maintains a balance between access to liquid water and adequate protection from freezing. In the absence of precipitation, the interior of weathered basaltic glass is an extreme and life-limiting environment for microorganisms on Earth and other planets.

Effects of experimental variables on the nonlinear harmonic generation technique.

Harmonic generation is a promising technique for measuring small changes in the microstructure of components. Its extreme sensitivity is a benefit for detection, but results in a high degree of variability in any measurements taken. This paper characterizes the effects of experimental variables throughout the measurement signal path, establishing their relative importance and making suggestions for the best way to take measurements using harmonic generation. A model is used to predict the harmonic amplitude as a function of position and thereby account for alignment inaccuracy, explaining the effects of this key experimental variable. Finally, the potential effect of all of the variables on damage detection is discussed.

Scattering of plane guided waves obliquely incident on a straight feature with uniform cross-section.

A frequency-domain finite element (FE) method is presented for modeling the scattering of plane guided waves incident on an infinitely-long, straight feature with uniform cross-section in a planar host waveguide. The method utilizes a mesh of 2-dimensional finite elements with harmonic shape functions in the perpendicular direction. The model domain comprises a cross-section through the feature and short lengths of the adjoining host waveguide. A spatial frequency equal to the wavenumber of the desired incident mode multiplied by the sine of the desired incidence angle is prescribed for the element shape functions. An integral representation of the incident mode is used to determine a suitable system of harmonic forces to uniquely excite that mode. These are applied at nodes through the thickness of the host waveguide on one side of the feature. The displacement field is measured at nodes through the thickness of the host waveguide on either side of the feature and decomposed into reflected and transmitted modes. The cases of guided wave transmission in a featureless waveguide and the reflection of guided waves from a free-edge are examined as validation cases. Finally, the results for transmission at an adhesively-bonded stiffener are presented and compared with experimental measurements.