Forward and Inverse Modeling Frameworks for Nondestructive Evaluation of Materials with Resonant Ultrasound Spectroscopy

The objective of this dissertation is the development of both forward and inverse modeling frameworks that extend the nondestructive evaluation (NDE) capability of resonant ultrasound spectroscopy (RUS) for materials science applications through utilization of modern computational resources and a rigorous application of the fundamental physics of mechanical resonance. First, a forward modeling framework (FMF) based on 3D linear-elastic finite element models is developed to explain the complex manner in which resonance frequencies of a specimen change as damage is accumulated. Numerous examples of damage common to Ni-based superalloys for structural applications in extreme thermo-mechanical environments, like those found in turbine engines, are specifically addressed including: creep, fatigue and recrystallization. Then, an inverse modeling framework (IMF) devised with the goal of quantitative NDE of materials based on RUS measured resonance frequencies is introduced. Built upon a full-Bayesian approach to the inverse problem, the novel IMF devised here affords substantially simplified experimental methods by estimating elastic constants and crystal orientation parameters simultaneously. The potential of the IMF is demonstrated by evaluating a series of novel Co and CoNi-based single crystal superalloys, with robust convergence behavior as compared to optimizer-based approaches described in the literature. Together, the finite element-based FMF and the Bayesian IMF demonstrate the immense value and insight gained by coupling experiments with physics-based models for state-of-the-art materials characterization and NDE

Process Compensated Resonance Testing Modeling for Damage Evolution and Uncertainty Quantification

Process Compensated Resonance Testing (PCRT) is a nondestructive evaluation method that measures and analyzes the resonance frequencies of a component for material state characterization, defect detection and process monitoring. PCRT inspections of gas turbine engine components have demonstrated the sensitivity of resonance frequencies to manufacturing defects and in-service thermal and mechanical damage. Prior work on PCRT modeling has developed forward modeling and model inversion techniques that simulate the effects of geometry variation, material property variation, and damage on Mar-M-247 nickel-based superalloy samples. Finite element method (FEM) forward model simulations predicted the effects of variation in geometry, material properties and damage on resonance frequencies. Model inversion used measured resonance frequencies to characterize the material state of components. Parallel work developed a process for uncertainty quantification (UQ) in PCRT models and measurements. The UQ process evaluated the propagation of uncertainty from various sources, identified the most significant uncertainty sources, and enabled uncertainty mitigation to improve model and measurement accuracy. Current efforts have expanded on those developments in several areas. One-factor-at-a-time (OFAT) forward model simulations were conducted on cylindrical dog bone coupons made from Mar-M-247. The simulations predicted the resonance frequency response to variation in geometry, elastic properties, crystallographic orientation, creep strain and cracking. The OFAT studies were followed by forward model Monte Carlo simulations that predicted the effects of multiple, concurrent sources of variation and damage on resonance frequencies, allowing characterization of virtual populations and quantification of uncertainty propagation. The Monte Carlo simulation design points were used to demonstrate the generation of a virtual database of components for training PCRT inspection applications, or “sorting modules.” Virtual database training sets can potentially overcome the limitations imposed by the availability of components and material states for training sets based on physical examples. Forward modeling tools and techniques were applied to titanium to simulate the effects of material variation, damage, and crystallographic texture. Forward modeling was also applied to more complex geometries, including a notional turbine blade, to demonstrate the application of modeling tools to shapes representative of gas turbine engine components. Model inversion tools and techniques have also advanced under the current effort. Prior inversion methods relied on iterative fitting to polynomial expressions for simple geometries and bulk material properties. Current efforts have demonstrated FEM-based model inversion which allows characterization of complex shapes and material states. FEM-based design spaces were generated, model inversion was carried out for surrogate modeled resonance spectra, and inversion performance was evaluated. Analysis of PCRT modeling results led to the development of automated resonance mode matching tools based on the calculation of modal assurance criteria (MAC) values, mode shape displacement metrics and Hungarian Algorithm sorting methods

Bayesian inference of elastic properties with resonant ultrasound spectroscopy.

Bayesian modeling and Hamiltonian Monte Carlo (HMC) are utilized to formulate a robust algorithm capable of simultaneously estimating anisotropic elastic properties and crystallographic orientation of a specimen from a list of measured resonance frequencies collected via Resonance Ultrasound Spectroscopy (RUS). Unlike typical optimization procedures which yield point estimates of the unknown parameters, computing a Bayesian posterior yields probability distributions for the unknown parameters, and HMC is an efficient way to compute this posterior. The algorithms described are demonstrated on RUS data collected from two parallelepiped specimens of structural metal alloys. First, the elastic constants for a specimen of fine-grain polycrystalline Ti-6Al-4 V with random crystallographic texture and isotropic elastic symmetry are estimated. Second, the elastic constants and crystallographic orientation for a single crystal Ni-based superalloy CMSX-4 specimen are accurately determined, using only measurements of the specimen geometry, mass, and resonance frequencies. The unique contributions of this paper are as follows: the application of HMC for sampling the Bayesian posterior of a probabilistic RUS model, and the procedure for simultaneous estimation of elastic constants and lattice-specimen misorientation. Compared to previous approaches these algorithms demonstrate superior convergence behavior, particularly when the initial parameterization is unknown, and enable substantially simplified experimental procedures

Process Compensated Resonance Testing Modeling for Damage Evolution and Uncertainty Quantification

Process Compensated Resonance Testing (PCRT) is a nondestructive evaluation method that measures and analyzes the resonance frequencies of a component for material state characterization, defect detection and process monitoring. PCRT inspections of gas turbine engine components have demonstrated the sensitivity of resonance frequencies to manufacturing defects and in-service thermal and mechanical damage. Prior work on PCRT modeling has developed forward modeling and model inversion techniques that simulate the effects of geometry variation, material property variation, and damage on Mar-M-247 nickel-based superalloy samples. Finite element method (FEM) forward model simulations predicted the effects of variation in geometry, material properties and damage on resonance frequencies. Model inversion used measured resonance frequencies to characterize the material state of components. Parallel work developed a process for uncertainty quantification (UQ) in PCRT models and measurements. The UQ process evaluated the propagation of uncertainty from various sources, identified the most significant uncertainty sources, and enabled uncertainty mitigation to improve model and measurement accuracy. Current efforts have expanded on those developments in several areas. One-factor-at-a-time (OFAT) forward model simulations were conducted on cylindrical dog bone coupons made from Mar-M-247. The simulations predicted the resonance frequency response to variation in geometry, elastic properties, crystallographic orientation, creep strain and cracking. The OFAT studies were followed by forward model Monte Carlo simulations that predicted the effects of multiple, concurrent sources of variation and damage on resonance frequencies, allowing characterization of virtual populations and quantification of uncertainty propagation. The Monte Carlo simulation design points were used to demonstrate the generation of a virtual database of components for training PCRT inspection applications, or “sorting modules.” Virtual database training sets can potentially overcome the limitations imposed by the availability of components and material states for training sets based on physical examples. Forward modeling tools and techniques were applied to titanium to simulate the effects of material variation, damage, and crystallographic texture. Forward modeling was also applied to more complex geometries, including a notional turbine blade, to demonstrate the application of modeling tools to shapes representative of gas turbine engine components. Model inversion tools and techniques have also advanced under the current effort. Prior inversion methods relied on iterative fitting to polynomial expressions for simple geometries and bulk material properties. Current efforts have demonstrated FEM-based model inversion which allows characterization of complex shapes and material states. FEM-based design spaces were generated, model inversion was carried out for surrogate modeled resonance spectra, and inversion performance was evaluated. Analysis of PCRT modeling results led to the development of automated resonance mode matching tools based on the calculation of modal assurance criteria (MAC) values, mode shape displacement metrics and Hungarian Algorithm sorting methods.</p

Elastic Properties of Novel Co- and CoNi-Based Superalloys Determined through Bayesian Inference and Resonant Ultrasound Spectroscopy

Bayesian inference is employed to precisely evaluate single crystal elastic properties of novel γ- γ′ Co- and CoNi-based superalloys from simple and non-destructive resonant ultrasound spectroscopy (RUS) measurements. Nine alloys from three Co-, CoNi-, and Ni-based alloy classes were evaluated in the fully aged condition, with one alloy per class also evaluated in the solution heat-treated condition. Comparisons are made between the elastic properties of the three alloy classes and among the alloys of a single class, with the following trends observed. A monotonic rise in the c44 (shear) elastic constant by a total of 12 pct is observed between the three alloy classes as Co is substituted for Ni. Elastic anisotropy (A) is also increased, with a large majority of the nearly 13 pct increase occurring after Co becomes the dominant constituent. Together the five CoNi alloys, with Co:Ni ratios from 1:1 to 1.5:1, exhibited remarkably similar properties with an average A 1.8 pct greater than the Ni-based alloy CMSX-4. Custom code demonstrating a substantial advance over previously reported methods for RUS inversion is also reported here for the first time. CmdStan-RUS is built upon the open-source probabilistic programing language of Stan and formulates the inverse problem using Bayesian methods. Bayesian posterior distributions are efficiently computed with Hamiltonian Monte Carlo (HMC), while initial parameterization is randomly generated from weakly informative prior distributions. Remarkably robust convergence behavior is demonstrated across multiple independent HMC chains in spite of initial parameterization often very far from actual parameter values. Experimental procedures are substantially simplified by allowing any arbitrary misorientation between the specimen and crystal axes, as elastic properties and misorientation are estimated simultaneously