The high frequency flexural ultrasonic transducer for transmitting and receiving ultrasound in air

Flexural ultrasonic transducers are robust and low cost sensors that are typically used in industry for distance ranging, proximity sensing and flow measurement. The operating frequencies of currently available commercial flexural ultrasonic transducers are usually below 50 kHz. Higher operating frequencies would be particularly beneficial for measurement accuracy and detection sensitivity. In this paper, design principles of High Frequency Flexural Ultrasonic Transducers (HiFFUTs), guided by the classical plate theory and finite element analysis, are reported. The results show that the diameter of the piezoelectric disc element attached to the flexing plate of the HiFFUT has a significant influence on the transducer's resonant frequency, and that an optimal diameter for a HiFFUT transmitter alone is different from that for a pitch-catch ultrasonic system consisting of both a HiFFUT transmitter and a receiver. By adopting an optimal piezoelectric diameter, the HiFFUT pitch-catch system can produce an ultrasonic signal amplitude greater than that of a non-optimised system by an order of magnitude. The performance of a prototype HiFFUT is characterised through electrical impedance analysis, laser Doppler vibrometry, and pressure-field microphone measurement, before the performance of two new HiFFUTs in a pitch-catch configuration is compared with that of commercial transducers. The prototype HiFFUT can operate efficiently at a frequency of 102.1 kHz as either a transmitter or a receiver, with comparable output amplitude, wider bandwidth, and higher directivity than commercially available transducers of similar construction

Additive manufacturing (3D print) of air-coupled diaphragm ultrasonic transdrucers

Air-coupled ultrasound is a non-contact technology that has become increasingly common in Non Destructive Evaluation (NDE) and material evaluation. Normally, the bandwidth of a conventional transducer can be enhanced, but with a cost to its sensitivity. However, low sensitivity is very disadvantageous in air-coupled devices. This thesis proposes a methodology for improving the bandwidth of an air-coupled micro-machined ultrasonic transducer (MUT) without sensitivity loss by connecting a number of resonating pipes of various length to a cavity in the backplate. This design is inspired by the pipe organ musical instrument, where the resonant frequency (pitch) of each pipe is mainly determined by its length. The −6 dB bandwidth of the "pipe organ" inspired air-coupled transducer is 55.7% and 58.5% in transmitting and receiving modes, respectively, which is ∼5 times wider than a custom-built standard device. After validating the concept via a series of single element low-frequency prototypes, two improved designs: the multiple element and the high-frequency single element pipe organ transducers were simulated in order to tailor the pipe organ design to NDE applications.Although the simulated and experimental performance of the pipe organ inspired transducers are proved to be significantly better than the conventional designs, conventional micro-machined technologies are not able to satisfy their required 3D manufacturing resolution. In recent years, there has been increasing interest in using additive manufacturing (3D printing) technology to fabricate sensors and actuators due to rapid prototyping, low-cost manufacturing processes, customized features and the ability to create complex 3D geometries at micrometre scale. This work combines the ultrasonic diaphragm transducer design with a novel stereolithographic additive manufacturing technique. This includes developing a multi-material fabrication process using a commercial digital light processing printer and optimizing the formula of custom-built functional (conductive and piezoelectric) materials. A set of capacitive acoustic and ultrasonic transducers was fabricated using the additive manufacturing technology. The additive manufactured capacitive transducers have a receiving sensitivity of up to 0.4 mV/Pa at their resonant frequency.Air-coupled ultrasound is a non-contact technology that has become increasingly common in Non Destructive Evaluation (NDE) and material evaluation. Normally, the bandwidth of a conventional transducer can be enhanced, but with a cost to its sensitivity. However, low sensitivity is very disadvantageous in air-coupled devices. This thesis proposes a methodology for improving the bandwidth of an air-coupled micro-machined ultrasonic transducer (MUT) without sensitivity loss by connecting a number of resonating pipes of various length to a cavity in the backplate. This design is inspired by the pipe organ musical instrument, where the resonant frequency (pitch) of each pipe is mainly determined by its length. The −6 dB bandwidth of the "pipe organ" inspired air-coupled transducer is 55.7% and 58.5% in transmitting and receiving modes, respectively, which is ∼5 times wider than a custom-built standard device. After validating the concept via a series of single element low-frequency prototypes, two improved designs: the multiple element and the high-frequency single element pipe organ transducers were simulated in order to tailor the pipe organ design to NDE applications.Although the simulated and experimental performance of the pipe organ inspired transducers are proved to be significantly better than the conventional designs, conventional micro-machined technologies are not able to satisfy their required 3D manufacturing resolution. In recent years, there has been increasing interest in using additive manufacturing (3D printing) technology to fabricate sensors and actuators due to rapid prototyping, low-cost manufacturing processes, customized features and the ability to create complex 3D geometries at micrometre scale. This work combines the ultrasonic diaphragm transducer design with a novel stereolithographic additive manufacturing technique. This includes developing a multi-material fabrication process using a commercial digital light processing printer and optimizing the formula of custom-built functional (conductive and piezoelectric) materials. A set of capacitive acoustic and ultrasonic transducers was fabricated using the additive manufacturing technology. The additive manufactured capacitive transducers have a receiving sensitivity of up to 0.4 mV/Pa at their resonant frequency

An annular array with fiber composite microstructure for far field NDT imaging applications

This paper describes the design and fabrication of a reduced element count annular array for far field NDT imaging applications, built with a random fiber piezoelectric composite microstructure. An annular array design is considered, spatially it offers axi-symmetric layout while reducing number of array elements, which could potentially result in a significant reduction in the cost and complexity of building an ultrasonic volumetric imaging system. Modelling and preliminary experimental results are presented to evaluate the feasibility of this approach

Properties of photocured epoxy resin materials for application in piezoelectric ultrasonic transducer matching layers

This paper describes the acoustic properties of a range of epoxy resins prepared by photocuring that are suitable for application in piezoelectric ultrasonic transducer matching layers. Materials, based on blends of diglycidyl ether of Bisphenol A and 1,4-cyclohexanedimethanol diglycidyl ether, are described. Furthermore, in order to vary the elastic character of the base resin, samples containing polymer microspheres or barium sulfate particles are also described. The acoustic properties of the materials are determined by a liquid coupled through transmission methodology, capable of determining the velocity and attenuation of longitudinal and shear waves propagating in an isotropic layer. Measured acoustic properties are reported which demonstrate materials with specific acoustic impedance varying in the range 0.88–6.25 MRayls. In the samples comprising blends of resin types, a linear variation in the acoustic velocities and density was observed. In the barium sulfate filled samples, acoustic impedance showed an approximately linear variation with composition, reflecting the dominance of the density variation. While such variations can be predicted by simple mixing laws, relaxation and scattering effects influence the attenuation in both the blended and filled resins. These phenomena are discussed with reference to dynamic mechanical thermal analysis and differential scanning calorimetry of the samples

Thick film PZT transducer arrays for particle manipulation

This paper reports the fabrication and evaluation of a two-dimensional thick film PZT ultrasonic transducer array operating at about 7.5 MHz for particle manipulation. All layers on the array are screen-printed and sintered on an Al2O3 substrate without further processes or patterning. The measured dielectric constant of the PZT is 2250 ± 100, and the dielectric loss is 0.09 ± 0.005 at 10 kHz. Finite element analysis has been used to predict the behaviour of the array and impedance spectroscopy and laser vibrometry have been used to characterise its performance. The measured deflection of a single activate element is on the order of tens of nanometres with 20 Vpp input. Particle manipulation experiments have been performed by coupling the thick film array to a capillary containing polystyrene microspheres in water

Surface micromachined capacitive ultrasonic transducers

Cataloged from PDF version of article.The current state of a novel technology, surface microfabricated ultrasonic transducers, is reported. Experiments demonstrating both air and water transmission are presented. Air-coupled longitudinal wave transmission through aluminum is demonstrated, implying a 110 dB dynamic range for transducers at 2.3 MHz in air. Water transmission experiments from 1 to 20 MHz are performed, with a measured 60 dB SNR at 3 MHz. A theoretical model is proposed that agrees well with observed transducer behavior. Most significantly, the model is used to demonstrate that microfabricated ultrasonic transducers constitute an attractive alternative to piezoelectric transducers in many applications

Investigating the motility of Dictyostelium discodeum using high frequency ultrasound as a method of manipulation

Cell motility is an essential process in the development of all organisms. The earliest stages of embryonic development involve massive reconfigurations of groups of cells to form the early body structures. Embryos are very complex systems, and therefore to investigate the molecular and cellular basis of development a simpler genetically tractable model system is used. The social amoeba Dictyostelium Discoideum is known to chemotax up a chemical gradient. From previous work, it is clear that cells generate forces in the nN range. This is above the limit of optical tweezers and therefore we are investigating the use of acoustic tweezers instead. In this paper, we present recent progress of the investigation in to the use of acoustic tweezers for the characterisation of cell motility and forces. We will describe the design, modelling and fabrication of several devices. All devices use high frequency (>15MHz) ultrasound to exert a force on the cells to position and/or stall them. Also, each device is designed to be suitable for the life-sciences laboratory where form-factor and sterility is concerned. A transducer (LiNo) operating at 24 MHz excites resonant acoustic modes in a rectangular glass capillary (100um by 2mm). This device is used to alter the directionality of the motile cells inside the fluid filled capillary. A quarter-ring PZT26 transducer operating at 20.5MHz is shown to be useful for manipulating cells using axial acoustic radiation forces. This device is used to exert a force on cells and shown to pull them away from a coverslip. The presented devices show promise for the manipulation of cells in suspension. Currently the forces produced are below that required for adherent cells; the reasons for this are discussed. We also report on other issues that arise when using acoustic waves for manipulating biological samples such as streaming and heating

Acousto-ultrasonic nondestructive evaluation of materials using laser beam generation and detection

The acousto-ultrasonic method has proven to be a most interesting technique for nondestructive evaluation of the mechanical properties of a variety of materials. Use of the technique or a modification thereof, has led to correlation of the associated stress wave factor with mechanical properties of both metals and composite materials. The method is applied to the nondestructive evaluation of selected fiber reinforced structural composites. For the first time, conventional piezoelectric transducers were replaced with laser beam ultrasonic generators and detectors. This modification permitted true non-contact acousto-ultrasonic measurements to be made, which yielded new information about the basic mechanisms involved as well as proved the feasibility of making such non-contact measurements on terrestrial and space structures and heat engine components. A state-of-the-art laser based acousto-ultrasonic system, incorporating a compact pulsed laser and a fiber-optic heterodyne interferometer, was delivered to the NASA Lewis Research Center