Design and analysis of an open-ended waveguide probe for material characterization

Nondestructive evaluation of stratified (layered) composite structures at microwave and millimeter wave frequencies is of great interest in many applications where simultaneous determination of the complex dielectric properties and thicknesses of multiple layers is desired. Open-ended rectangular waveguide probes are effective tools for this purpose. The technique requires a full-wave electromagnetic model that accurately calculates the complex reflection coefficient as a function of frequency and material properties. Subsequently, this information is used in conjunction with the measured complex reflection coefficient to evaluate the sought for material properties. This thesis presents simulated and measured data to investigate the influence that measurement system noise, which contaminates the measured complex reflection coefficient, has on estimating material properties. It will be shown however, that the foremost contributor to errors in estimating material properties is not due to system noise, but rather, is due to an inconsistency between the electromagnetic model and the measurement setup. More specifically, the electromagnetic model assumes an infinite waveguide flange while measurements are conducted using a finite-size flange. Consequently, the results of the model and those from measurements may not be sufficiently alike for accurate dielectric property and thickness evaluation. The work presented here investigates the effect of using an open-ended waveguide with a standard finite-sized flange on the error in evaluating the complex dielectric properties of a composite structure. Additionally, the design of a novel flange that markedly reduces this undesired effect by producing very similar electric field properties, at the flange aperture, to those created by an infinite flange will be presented and verified in measurement --Abstract, page iii

Multimode Solution for the Reflection Properties of an Open-Ended Rectangular Waveguide Radiating into a Dielectric Half-Space: The Forward and Inverse Problems

Open-ended rectangular waveguides are extensively used in nondestructive dielectric material evaluation. The dielectric properties of an infinite-half space of a material are calculated from the measured reflection properties referenced to the waveguide aperture. This calculation relies on a theoretical and numerical derivation of the reflection coefficient likewise referenced to the waveguide aperture. Most of these derivations assume the dominant mode field distribution across the waveguide aperture. However, when dealing with low permittivity and low loss dielectric materials, there may exist significant errors when calculating the dielectric properties from the measured reflection coefficient. These errors have also shown to be more significant in the upper frequency portion of a waveguide band. More accurate results are obtained when higher order modes are considered in addition to the dominant waveguide mode. However, most studies incorporating higher-order modes have used various approximations when calculating the reflection properties and have not provided a full discussion on the influences of dielectric properties of the infinite-half space and the frequency of operation. This paper gives a rigorous and exact formulation in which the dominant mode and the evanescent higher-order modes are used as basis functions to obtain the solution for the reflection coefficient at the waveguide aperture. The analytic formulation uses Fourier analysis in addition to the forcing of the necessary boundary conditions at the waveguide aperture. The solution also readily accounts for the complex contributions of both TE and TM higher-order modes. Finally, the influences of the dielectric properties of the infinite-half space and the frequency of operation are investigated

Advanced microwave embedded sensors for infrastructure health monitoring

Microwave sensor systems have been widely investigated for many applications due to their ability to provide non-destructive, noncontact, one-sided and wireless testing. Among these applications infrastructure health monitoring of bridges, building, and dams using microwave sensors, which are mounted on or embedded in composite structures of infrastructure has been attracting an increasing interest. One of the current needs of infrastructure health monitoring includes the detection and monitoring of disbonding and gaps in concrete-based structures, which are also required for simultaneous characterization of concrete. A recently proposed microwave sensor technique exploiting a relatively simple waveguide sensor embedded in a concrete-metal structure such as a concrete-filled steel tube exhibited great potential. However, it suffers from a few drawbacks that need to be solved. This thesis aims to develop and investigate advanced microwave embedded sensors to solve main problems in the current microwave sensory technique including characterization of concrete in concrete-based structures at different stage of its life, size of the interface under inspection, detection and monitoring of a small gap between concrete and dielectric material surfaces and sensitivity to gaps. To achieve this aim the following five research contributions have been made: The first contribution is the methodology for the determination of the complex dielectric permittivity of concrete using both measurement data and simulation results at different stages (fresh, early-aged and dry) of its life. Firstly, it is developed and tested for a single flanged open-ended waveguide sensor with a hardened concrete specimen, and then the methodology is modified for the developed sensors embedded in concrete-based composite structures with fresh, early-age and dry concrete. Modern computational tool CST Microwave Studio and a performance network analyser are used for simulation and measurement, respectively, throughout this research work. The second contribution is a dual waveguide sensor, which is proposed, designed and applied for the detection and monitoring of a small gap in concrete-metal composite structures. It consists of two waveguide sections and a metal plate and uses the transmission of electromagnetic waves along gap when it occurs between the metal plate and concrete surfaces. It provides more measurement data than the single waveguide sensor for characterising concrete-metal structures such as transmission properties of guided waves along the gap and reflection properties of the metal–concrete interface at two different places at the same stage of concrete. As a result, the proposed sensor increases the size of the interface under inspection and sensitivity to the gap using the magnitude of reflection coefficient and magnitude of transmission coefficient together and/or independently. The third contribution is the design and application of a dual waveguide sensor with rectangular dielectric insertions that is proposed and tested for the characterisation of concrete–metal structures at different stages of the concrete life including its fresh stage. The dielectric insertions are designed and implanted in the waveguide sections in such a way that they create the resonant response of the sensor and prevent water and concrete entering the sections. The resonant properties of the sensor allow long-term monitoring of the concrete hydration, including the detection of the transition from fresh to hardened concrete on its first day. The proposed sensor along with the modified algorithm provides the determination of the complex dielectric permittivity of fresh concrete. The fourth contribution is a dual waveguide sensor with tapered dielectric insertions. Each tapered dielectric insertion is designed with a tapered part and rectangular part to reduce wave reflection from the insertions over an entire frequency band. The proposed sensor has improved performance at the resonant responses of a quarter-wavelength resonator formed by an open end at the tapered part and shorted end at the rectangular part of each insertion. The last contribution is the development of dual waveguide sensors with attached dielectric layer and their application for the detection and monitoring of gap between dielectric materials and concrete in metal-dielectric layer-concrete composites as well as the determination of complex dielectric permittivity of concrete at different stages of its life. One of the most attractive designs is the sensor with empty waveguide sections due to its simplicity and robustness, and capability of the layer for preventing penetration of the obstacles and water, and for optimization of the sensor. On the other hand, the sensors with dielectric insertions and the layer demonstrate a significantly higher magnitude of transmission coefficient. The proposed DWSs can be applied to characterise fresh concrete in a dielectric mould or on-line, and to investigate the shrinkage of different categories of concrete

Review of current guided wave ultrasonic testing (GWUT) limitations and future directions

Damage is an inevitable occurrence in metallic structures and when unchecked could result in a catastrophic breakdown of structural assets. Non-destructive evaluation (NDE) is adopted in industries for assessment and health inspection of structural assets. Prominent among the NDE techniques is guided wave ultrasonic testing (GWUT). This method is cost-effective and possesses an enormous capability for long-range inspection of corroded structures, detection of sundries of crack and other metallic damage structures at low frequency and energy attenuation. However, the parametric features of the GWUT are affected by structural and environmental operating conditions and result in masking damage signal. Most studies focused on identifying individual damage under varying conditions while combined damage phenomena can coexist in structure and hasten its deterioration. Hence, it is an impending task to study the effect of combined damage on a structure under varying conditions and correlate it with GWUT parametric features. In this respect, this work reviewed the literature on UGWs, damage inspection, severity, temperature influence on the guided wave and parametric characteristics of the inspecting wave. The review is limited to piezoelectric transduction unit. It was keenly observed that no significant work had been done to correlate the parametric feature of GWUT with combined damage effect under varying conditions. It is therefore proposed to investigate this impending tas

Radio frequency non-destructive testing and evaluation of defects under insulation

PhD ThesisThe use of insulation such as paint coatings has grown rapidly over the past decades. However, defects and corrosion under insulation (CUI) still present challenges for current non-destructive testing and evaluation (NDT&E) techniques. One of such challenges is the large lift-off introduced by thick insulation layer. Inaccessibility due to insulation leads corrosion and defects to be undetected, which can lead to catastrophic failure. Furthermore, lift-off effects due to the insulation layers reduce the sensitivities. The limitations of existing NDT&E techniques heighten the need for novel approaches to the characterisation of corrosion and defects under insulation. This research project is conducted in collaboration with International Paint®, and a radio frequency non-destructive evaluation for monitoring structural condition is proposed. High frequency (HF) passive RFID in conjunction with microwave NDT is proposed for monitoring and imaging under insulation. The small-size, battery-free and cost-efficient nature of RFID makes it attractive for long-term condition monitoring. To overcome the limitations of RFID-based sensing system such as effective monitoring area and lift-off tolerance, microwave NDT is proposed for the imaging of larger areas under thick insulation layers. Experimental studies are carried out in conjunction with specially designed mild steel sample sets to demonstrate the detection capabilities of the proposed systems. The contributions of this research can be summarised as follows. Corrosion detection using HF passive RFID-based sensing and microwave NDT is demonstrated in experimental feasibility studies considering variance in surface roughness, conductivity and permeability. The lift-off effects introduced by insulation layers are reduced by applying feature extraction with principal component analysis and non-negative matrix factorisation. The problem of thick insulation layers is overcome by employing a linear sweep frequency with PCA to improve the sensitivity and resolution of microwave NDT-based imaging. Finally, the merits of microwave NDT are identified for imaging defects under thick insulation in a realistic test scenario. In conclusion, HF passive RFID can be adapted for long term corrosion monitoring of steel under insulation, but sensing area and lift-off tolerance are limited. In contrast, the microwave NDT&E has shown greater potential and capability for monitoring corrosion and defects under insulation