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

Venting in the comparative study of flexural ultrasonic transducers to improve resilience at elevated environmental pressure levels

The classical form of a flexural ultrasonic transducer is a piezoelectric ceramic disc bonded to a circular metallic membrane. This ceramic induces vibration modes of the membrane for the generation and detection of ultrasound. The transducer has been popular for proximity sensing and metrology, particularly for industrial applications at ambient pressures around 1 bar. The classical flexural ultrasonic transducer is not designed for operation at elevated pressures, such as those associated with natural gas transportation or petrochemical processes. It is reliant on a rear seal which forms an internal air cavity, making the transducer susceptible to deformation through pressure imbalance. The application potential of the classical transducer is therefore severely limited. In this study, a venting strategy which balances the pressure between the internal transducer structure and the external environment is studied through experimental methods including electrical impedance analysis and pitch-catch ultrasound measurement. The vented transducer is compared with a commercial equivalent in air towards 90 bar. Venting is shown to be viable for a new generation of low cost and robust industrial ultrasonic transducers, suitable for operation at high environmental pressure levels

A closed-loop operation to improve GMR sensor accuracy

Giant magnetoresistance (GMR) magnetic field sensors are compact, low power, high sensitivity devices that are low cost and have very simple supporting electronics. One of the disadvantages of GMR sensors can be their nonlinearity, hysteresis, and temperature-dependent output, which can reduce measurement accuracy. This paper presents an approach to improve the measurement accuracy of GMR sensors using a closed-loop circuit, which includes the sensor, a biasing coil, and a feedback circuit. The current in the biasing coil is actively changed to ensure that the component of magnetic field along the sensitive axis of the device is held constant, so that as the external magnetic field or orientation of the GMR sensor changes, the output of GMR sensor remains stable. In this way, the external magnetic field component along the sensitive axis of the device can be calculated by measuring the current in the biasing coil surrounding the GMR sensor, regardless of the hysteresis and nonlinearly of GMR sensor. The linearity and the accuracy of magnetic field measurements using a GMR sensor are significantly improved and a hardware prototype has been constructed and tested under a reference magnetic field

Shear horizontal (SH) ultrasound wave propagation around smooth corners

Shear horizontal (SH) ultrasound guided waves are being used in an increasing number of non-destructive testing (NDT) applications. One advantage SH waves have over some wave types, is their ability to propagate around curved surfaces with little energy loss; to understand the geometries around which they could propagate, the wave reflection must be quantified. A 0.83 mm thick aluminium sheet was placed in a bending machine, and a shallow bend was introduced. Periodically-poled magnet (PPM) electromagnetic acoustic transducers (EMATs), for emission and reception of SH waves, were placed on the same side of the bend, so that reflected waves were received. Additional bending of the sheet demonstrated a clear relationship between bend angles and the reflected signal. Models suggest that the reflection is a linear superposition of the reflections from each bend segment, such that sharp turns lead to a larger peak-to-peak amplitude, in part due to increased phase coherence

Mode mixing in shear horizontal ultrasonic guided waves

SH guided waves are used increasingly for non-destructive testing (NDT) applications, particularly for pipes and pipe supports using circumferentially guided wave modes. In practical implementations, it is not always straightforward to ensure single-mode operation and this requires consideration when interpreting results. During shear horizontal (SH) wave generation or SH guided wave interaction with geometrical changes or defects, multiple SH guided wave modes may be produced, depending on the shear wave speed, the frequency of operation, the thickness of the sample and the transducer characteristics. This paper discusses the interference patterns created as the multiple SH modes mix (for both continuous tone generation and short bursts), and the problems caused by the interference patterns on applications such as NDT. In particular, the patterns can lead to defects being missed during an NDT inspection using SH waves, and a way to circumvent this problem is suggested

Analysis of electrical resonance distortion for inductive sensing applications

Resonating inductive sensors are increasingly popular for numerous measurement techniques, not least in non-destructive testing (NDT), due to the increased sensitivity obtained at frequencies approaching electrical resonance. The highly unstable nature of resonance limits the practical application of such methods while no comprehensive understanding exists of the resonance distorting behaviour in relation to typical measurements and environmental factors. In this paper, a study into the frequency spectrum behaviour of electrical resonance is carried out exploring the effect of key factors. These factors, known to distort the electrical resonance of inductive sensors, include proximity to (or lift-off from) a material surface, and the presence of discontinuities in the material surface. Critical features of resonance are used as metrics to evaluate the behaviour of resonance with lift-off and defects. Experimental results are compared to results from a 2D finite element analysis (FEA) model that geometrically mimics the inductive sensor used in the experiments, and to results predicted by an equivalent circuit transformer model. The findings conclusively define the physical phenomenon behind measurement techniques such as near electrical resonance signal enhancement (NERSE), and show that lift-off and defect resonance distortions are unique, measurable and can be equated to exclusive variations in the induced variables in the equivalence circuit model. The resulting understanding found from this investigation is critical to the future development and understanding of a complete model of electrical resonance behaviour, integral for the design of novel sensors, techniques and inversion models

Nonlinearity in the dynamic response of flexural ultrasonic transducers

Recent studies of the electro-mechanical behavior of flexural ultrasonic transducers have shown that their response can be considered as three distinct characteristic regions, the first building towards a steady state, followed by oscillation at the driving frequency in the steady state, before an exponential decay from the steady state at the transducer's dominant resonance frequency, once the driving force is removed. Despite the widespread industrial use of these transducers as ultrasonic proximity sensors, there is little published information on their vibration characteristics under different operating conditions. Flexual transducers are composed of a piezoelectric ceramic disc bonded to the inner surface of a metallic cap, the membrane of which bends in response to the high-frequency ceramic vibrations of the ceramic. Piezoelectric devices can be subject to nonlinear behavior, but there is no reported detail of the nonlinearity in flexural transducers. Experimental investigation through laser Doppler vibrometry shows strong nonlinearity in the vibration response, where resonance frequency reduces with increasing vibration amplitude

High frequency measurement of ultrasound using flexural ultrasonic transducers

Flexural ultrasonic transducers are a widely available type of ultrasonic sensor used for flow measurement, proximity, and industrial metrology applications. The flexural ultrasonic transducer is commonly operated in one of the axisymmetric modes of vibration in the low-kilohertz range, under 50 kHz, but there is an increasing demand for higher frequency operation, towards 300 kHz. At present, there are no reports of the measurement of high-frequency vibrations using flexural ultrasonic transducers. This research reports on the measurement of high-frequency vibration in flexural ultrasonic transducers, utilizing electrical impedance and phase measurement, laser Doppler vibrometry, and response spectrum analysis through the adoption of two flexural ultrasonic transducers in a transmit–receive configuration. The outcomes of this research demonstrate the ability of flexural ultrasonic transducers to measure high-frequency ultrasound in air, vital for industrial metrology

High power phased EMAT arrays for nondestructive testing of as-cast steel

A new high-power electromagnetic acoustic transducer (EMAT) solid state pulser system has been developed that is capable of driving up to 4 EMAT coils with programmable phase delays, allowing for focusing and steering of the acoustic field. Each channel is capable of supplying an excitation current of up to 1.75 kA for a pulse with a rise time of 1 μs. Finite element and experimental data are presented which demonstrate a signal enhancement by a factor of 3.5 (compared to a single EMAT coil) when using the system to transmit a longitudinal ultrasound pulse through a 22.5 cm thick as-cast steel slab sample. Further signal enhancement is demonstrated through the use of an array of detection EMATs, and a demonstration of artificial internal defect detection is presented on a thick steel sample. The design of this system is such that it has the potential to be employed at elevated temperatures for diagnostic measurements of steel during the continuous casting process

HiFFUTs for high temperature ultrasound

Flexural ultrasonic transducers have been widely used as proximity sensors and as part of industrial metrology systems. However, there is demand from industry for these transducers to have the capability to operate in both liquid and gas, at temperatures of 100-200°C and higher, significantly greater than those tolerated by current flexural transducers. Furthermore, flexural transducers tend to be designed for operation up to around 50 kHz, and the ability to operate at higher frequencies will open up new application and research areas. A limitation of current flexural transducers is the electromechanical driving element, usually a lead zirconate titanate piezoelectric ceramic, which experiences significantly reduced performance as temperature is increased. This investigation proposes a new type of flexural transducer, the HiFFUT, a high frequency flexural ultrasonic transducer, comprising a bismuth titanate ceramic for operation at high temperatures, that could be replaced by another suitable high Curie temperature piezoelectric material if required, bonded to the membrane with a high temperature adhesive. The dynamic characteristics of the HiFFUT are studied as a function of temperature, providing insights into its usefulness for industrial applications