Simulation of the influence of hydrophones used for the characterization of pressure field distribution in low frequency, high power ultrasonic reactor vessels

This paper describes the use of a finite element (FE) modeling approach to investigate the influence of different hydrophone designs in laboratory scale reactor vessels. In addition to conventional PVDF membrane and piezoceramic hydrophone, the performance of a conceptual array hydrophone, comprising a 2D matrix of PVDF array elements, will be simulated. The FE modeling concentrates on two issues: the disturbance to the field through the introduction of each hydrophone configuration; and their suitability and response to measuring non-linear effects. To simplify the model the ultrasonic transducer is not directly represented. Here, a pressure loading function is used as the excitation technique, with a sawtooth waveform applied for the simulation of the non-linear detection capability of each hydrophone configuration. The results from the simulation programme demonstrate that the dynamics of the reactor vessel are critical to optimize the performance of the ultrasonic system. In addition, the introduction of a hydrophone alters the wave propagation, and hence the field distribution beyond a given probe location. Nevertheless, the spatial pressure distribution at the active area remains reasonably accurate if within the useable bandwidth of the device. Accordingly, the broadband nature of the membrane device is suited to operation in both the linear and non-linear regimes, with the PVDF array membrane device offering a fast, convenient measurement of the pressure field distribution for industrial applications

Ultrasonic wave propagation in cylindrical vessels and implications for ultrasonic reactor design

Reactors in which processes are enhanced by ultrasound are hampered by the lack of a theoretical framework on their design. Simulation results of ultrasonic wave propagation in a cylindrical geometry are presented in this work, which are then used to develop guidelines for the design of ultrasonic reactors. These guidelines are used to design a new type of reactor with a novel geometry, operating at a frequency of 27kHz, 39kHz and 82kHz. This reactor is characterized using Weissler's reaction dosimetr

Investigating the influence of the constituent materials on the performance of periodic piezoelectric composite arrays

This paper describes a theoretical investigation into the influence of the constituent materials on periodic composite array transducer performance. A finite element (FE) model, configured in PZFlex, is used to analyze the performance of a wedge coupled array transducer operating into a steel component. Here, the improvements offered by new single crystal piezoelectric materials are compared to standard PZT‐based configurations. In addition, new passive polymer materials, possessing low longitudinal loss and high shear loss, are evaluated for their potential to significantly reduce inter‐element mechanical cross talk. The FE results illustrate the potential for the next generation of array transducers incorporating these new materials and this is highlighted in the A‐scan predictions from simulated defects

A 2D ultrasonic array design incorporating hexagonal-shaped elements for NDE applications

Contemporary 2D Ultrasonic arrays suffer from low SNR and limited steering capabilities. Yet, there is a great desire in the industry to increase the operational frequency, in order to enhance their volumetric imaging resolution. State-of-the art arrays use an orthogonal matrix of rectangular elements as this is a natural step forward from the conventional 1D array structure. The objective of this work is to evaluate properties of triangular, rather than rectangular ceramic pillars in a 1-3 connectivity piezoelectric composite for application in a hexagonal-element 2D array. A 3MHz prototype device exploiting new hexagonal substructure have been manufactured. Measured mechanical cross-coupling level is -21.9dB between neighbouring hexagonal elements, providing validation of simulation result. Corroboration between measured and FE modelled device behaviour is demonstrated

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

Total focussing method for volumetric imaging in immersion non destructive evaluation

This paper describes the use of a 550 (25x22) element 2MHz 2D piezoelectric composite array in immersion mode to image an aluminum test block containing a collection of artificial defects. The defects included a 1mm diameter side-drilled hole, a collection of 1mm slot defects with varying degrees of skew to the normal and a flat bottomed hole. The data collection was carried out using the full matrix capture; a scanning procedure was developed to allow the operation of the large element count array through a conventional 64-channel phased array controller. A 3D TFM algorithm capable of imaging in a dual media environment was implemented in MATLAB for the offline processing the raw scan data. This algorithm facilitates the creation of 3D images of defects while accounting for refraction effects at material boundaries. In each of the test samples interrogated the defects, and their spatial position, are readily identified using TFM. Defect directional information has been characterized using VTFM for defect exhibiting angles up to and including 45o of skew

Particle sizing in the process industry using Hertz-Zener impact theory and acoustic emission spectra

The cost of implementing real-time monitoring and control of industrial processes is a significant barrier for many companies. Acoustic techniques provide complementary information to optical spectroscopic sensors and have a number of advantages: they are relatively inexpensive, can be applied non-invasively, are non-destructive, multi-point measurements are possible, opaque samples can be analysed in containers that are made from opaque materials (e.g. steel or concrete) and the analysis can be conducted in real-time. In this paper a new theoretical model is proposed which describes the transport of particles in a stirred reactor, their collision with the reactor walls, the subsequent vibrations which are then transmitted through the vessel walls, and their detection by an ultrasonic transducer. The particle-wall impact is modelled using Hertz-Zener impact theory. Experimental data is then used in conjunction with this (forward) model to form an inverse problem for the particle size distribution using a least squares cost function. Application of an integral smoothing operator to the power spectra greatly enhances the accuracy and robustness of the approach. One advantage of this new approach is that since it operates in the frequency domain, it can cope with the industrially relevant case of many particle-wall collisions. The technique will be illustrated using data from a set of controlled experiments. In the first instance a set of simplified experiments involving single particles being dropped in air onto a substrate are utilised. The second set of experiments involves particles in a carrier fluid being stirred in a reactor vessel. In each case the approach is able to successfully recover the associated particle size

Teaching and learning analogue electronics in undergraduate courses : preliminary findings from the ETL project

This paper describes ongoing research into the teaching and learning of analogue electronics in three course units at two research-intensive universities. It draws on students' experiences of teaching and learning in analogue course units to explore the nature of the learning they were undertaking and examines the teaching-learning activities they found most supportive of their studying

Calibration of ultrasonic hardware for enhanced total focusing method imaging

Experimental variation from ultrasonic hardware is one source of uncertainty in measured ultrasonic data. This uncertainty leads to a reduction in the accuracy of images generated from these data. In this paper, a quick, easy-to-use and robust methodology is proposed to reduce this uncertainty in images generated using the total focusing method (TFM). Using a 128-element linear phased array, multiple full matrix capture (FMC) datasets of a planar reflection are used to characterise the experimental variation associated with each element index in the aperture. Following this, a methodology to decouple the time-domain error associated with transmission and reception at each element index is presented. These time-domain errors are then introduced into a simulated array model used to generate the two-way pressure profile from the array. The side-lobe-to-main-lobe energy ratio (SMER) and beam offset are used to quantify the impact of these measured time-domain errors on the pressure profile. This analysis shows that the SMER is raised by more than 6 dB and the beam is offset by more than 1 mm from its programmed focal position. This calibration methodology is then demonstrated using a steel non-destructive testing (NDT) sample with three side-drilled holes (SDHs). The time delay errors from transmission and reception are introduced into the time-of-flight (TOF) calculation for each ray path in the TFM. This results in an enhancement in the accuracy of defect localisation in the TFM image

Airborne broad-beam emitter from a capacitive transducer and a cylindrical structure

Beamwidth broadening of an ultrasonic air-coupled transducer is performed by an emitter constituted of an electrostatic transducer and of a cylinder with an opening at the top covering the surface of the transducer. The acoustic emission is thus forced through a hole smaller than the diameter of the transducer’s surface. In particular, a cylinder with an upper diameter of 10mm and a height of 5mm ensures the beam pattern of the final emitter is broad across a wide frequency range. Sound attenuation is reduced and lobes in the transducer’s beam pattern are cancelled. Beam broadening can improve range estimation techniques and ultrasonic sonar as a wider area can be inspected with one emission with no need for scanning