The effect of internal pipe wall roughness on the accuracy of clamp-on ultrasonic flow meters

Clamp-on transit-time ultrasonic flowmeters (UFMs) suffer from poor accuracy compared with spool-piece UFMs due to uncertainties that result from the in-field installation process. One of the important sources of uncertainties is internal pipe wall roughness which affects the flow profile and also causes significant scattering of ultrasound. This paper purely focuses on the parametric study to quantify the uncertainties (related to internal pipe wall roughness) induced by scattering of ultrasound and it shows that these effects are large even without taking into account the associated flow disturbances. The flowmeter signals for a reference clamp-on flowmeter setup were simulated using 2-D finite element analysis including simplifying assumptions (to simulate the effect of flow) that were deemed appropriate. The validity of the simulations was indirectly verified by carrying out experiments with different separation distances between ultrasonic probes. The error predicted by the simulations and the experimentally observed errors were in good agreement. Then, this simulation method was applied on pipe walls with rough internal surfaces. For ultrasonic waves at 1 MHz, it was found that compared with smooth pipes, pipes with only a moderately rough internal surface (with 0.2-mm rms and 5-mm correlation length) can exhibit systematic errors of 2 in the flow velocity measurement. This demonstrates that pipe internal surface roughness is a very important factor that limits the accuracy of clamp on UFMs

Simultaneous transmission and reception on all elements of an array: binary code excitation

Pulse-echo arrays are used in radar, sonar, seismic, medical and non-destructive evaluation. There is a trend to produce arrays with an ever-increasing number of elements. This trend presents two major challenges: (i) often the size of the elements is reduced resulting in a lower signal-to-noise ratio (SNR) and (ii) the time required to record all of the signals that correspond to every transmit–receive path increases. Coded sequences with good autocorrelation properties can increase the SNR while orthogonal sets can be used to simultaneously acquire all of the signals that correspond to every transmit–receive path. However, a central problem of conventional coded sequences is that they cannot achieve good autocorrelation and orthogonality properties simultaneously due to their length being limited by the location of the closest reflectors. In this paper, a solution to this problem is presented by using coded sequences that have receive intervals. The proposed approach can be more than one order of magnitude faster than conventional methods. In addition, binary excitation and quantization can be employed, which reduces the data throughput by roughly an order of magnitude and allows for higher sampling rates. While this concept is generally applicable to any field, a 16-element system was built to experimentally demonstrate this principle for the first time using a conventional medical ultrasound probe

Long-term stability of guided wave electromagnetic acoustic transducer systems

This article evaluates the long-term stability of a Lorentz force guided wave electromagnetic acoustic transducer. The specific application of the investigated electromagnetic acoustic transducer is pipeline health monitoring using low-frequency (27 kHz) long-range torsional guided waves. There is a concern that repeated swings in the temperature of the structure can cause irreversible changes in the transduction mechanism and therefore pose a risk to the long-term stability of transducers. In this article we report on guided wave signals acquired on a custom-built transducer while it was exposed to more than 90 heating cycles. The highest temperature that was reached during cycling was 80°C and the measurements were acquired over a 14-month period. At the end of the 1-year period, the transducer phase had changed by 23.32° and its amplitude by 3.7%. However, this change was not gradual and most of the change occurred early on, before the highest temperature was first reached in the temperature cycling process. The observed change after this was 6.08° phase shift and 0.9% amplitude change. The possible sources of output changes were investigated, and it was found that the mechanical properties of the contact layer between the electromagnetic acoustic transducer and the pipe surface was very important. A soft silicone interlayer performed best and was able to reduce temperature-induced phase changes in the monitored signals from a maximum of 80 degrees phase change to about 20 degrees phase change, a fourfold reduction

Development of a new, wireless acquisition system for EMATs compatible with the robotics operating system

The deployment of transducers to perform in situ inspections of industrial components can be complicated, and in many cases is still performed manually by a team of operators, which involves significant costs and can be dangerous. Robots capable of deploying probes in difficult to access locations are becoming available. Electromagnetic acoustic transducers (EMAT) are well suited to be used with robots since they are noncontact transducers that do not require a coupling medium, and can easily perform scans. However, existing acquisition systems for EMATs are generally not suitable to be directly mounted on robots. In this paper, a new wireless acquisition system for EMATs is presented. The system is standalone, it transmits the inspection data over WiFi, and is compatible with the robotics operating system (ROS). In addition, it is designed to be modular, small and lightweight so that it can be easily mounted on robots. The system design in terms of hardware and software is described in this paper. The resulting performance of the system is also reported

Co-located dual-wave ultrasonics for component thickness and temperature distribution monitoring

Permanently installed ultrasonic sensors have found increasing applications in the field of structural health monitoring (SHM), in particular with respect to thickness measurement and corrosion monitoring. As ultrasonic velocity is temperature dependent, the state and temperature distribution of a component contribute to much of the measurement uncertainties of an ultrasonic SHM system. On the other hand, the temperature dependency of ultrasonic velocity has also led to various temperature sensing methods for measuring temperature distributions within solid materials. While conventional ultrasound-based techniques can measure either a component’s thickness at a given temperature, or the internal temperature distributions at a given component thickness, measurement fluctuations and drifts can occur if both variables are set to change simultaneously. In this study, we propose a dual-wave approach to overcome the limitations of the existing methods. ‘Co-located’ shear and longitudinal pulse-echo measurements are used to simultaneously track the thickness change and through-thickness temperature variation of a steel plate in complex environmental conditions. Results of the verification experiments showed that, in the given conditions, the proposed dual-wave correction method could reduce thickness measurement uncertainties by approximately a factor of 5 and eliminate 90% of the drift in temperature predictions

Ultrasonic monitoring of friction contacts during shear vibration cycles

Complex high-value jointed structures such as aero-engines are carefully designed and optimized to prevent failure and maximise their life. In the design process, physically-based numerical models are employed to predict the nonlinear dynamic response of the structure. However, the reliability of these models is limited due to the lack of accurate validation data from metallic contact interfaces subjected to high-frequency vibration cycles. In this study, ultrasonic shear waves are used to characterise metallic contact interfaces during vibration cycles, hence providing new validation data for an understanding of the state of the friction contact. Supported by numerical simulations of wave propagation within the material, a novel experimental method is developed to simultaneously acquire ultrasonic measurements and friction hysteresis loops within the same test on a high-frequency friction rig. Large variability in the ultrasound reflection/transmission is observed within each hysteresis loop and is associated with stick/slip transitions. The measurement results reveal that the ultrasound technique can be used to detect stick and slip states in contact interfaces subjected to high-frequency shear vibration. This is the first observation of this type and paves the way towards real-time monitoring of vibrating contact interfaces in jointed structures, leading to a new physical understanding of the contact states and new validation data needed for improved nonlinear dynamic analyses

Ultrasonic guided wave monitoring of dendrite formation at electrode–electrolyte interface in aqueous zinc ion batteries

The formation of dendrite affects the cycling life of a battery and lead to malfunctions such as internal short-circuiting and thermal runaway events. However, existing methods to observe dendrite formation, such as X-ray computed tomography and scanning electron microscopy are either prohibitively complicated or unsuitable for long-term, in-situ monitoring. In this study we present a method which uses the fundamental shear-horizontal mode (SH0*) guided ultrasonic waves to independently monitor the status of the electrodes in a symmetric aqueous zinc-ion battery. Experimental measurements show that the velocity and attenuation of the ultrasonic wave on the opposing electrodes vary in the opposite senses during the cycling. While the velocity and attenuation changes can be partially reversed, a monotonic drift can also be observed with increasing number of cycles. Coupled with optical microscopy, the partially reversible oscillations can be associated with zinc stripping/plating. The irreversible drifting can be associated with the formation of ‘dead’ zinc dendrite. The technique shows clear sensitivity to the formation of dendrite, especially in the early stages (∼10 cycles) of charging and discharging processes. This work should inspire future research to enable quantitative assessment of the technique sensitivity and to improve its resolution