Multiple wavemode scanning for near and far-side defect characterisation

The combination of ultrasonic inspections using different wavemodes can give more information than is available with single mode inspection. In this work, the response of shear and Rayleigh waves to surface-breaking defects propagating on the near-side and far-side of a sample is investigated. The directivity of shear waves generated by a racetrack coil electromagnetic acoustic transducer (EMAT) is identified and used to set an ideal separation for a pair of transmit-receive EMATs. Defects are indicated by a reduction in the transmitted Rayleigh wave amplitude, and by blocking of the shear wave. Used together, these can identify features in the bulk wave behaviour which are due to near-face surface-breaking defects, and give a full picture of both surfaces. By using a combination of the two wavemodes, the angle of propagation and length of any near-side defects can additionally be identified. A scanning method for samples is proposed

Lamb wave near field enhancements for surface breaking defects in plates

Near field surface wave ultrasonic enhancements have previously been used to detect surface breaking defects in thick samples using Rayleigh waves. Here, we present analogous surface wave enhancements for Lamb waves propagating in plates. By tracking frequency intensities in selected regions of time-frequency representations, we observe frequency enhancement in the near field, due to constructive interference of the incident wave mode with those reflected and mode converted at the defect. This is explained using two test models; a square based notch and an opening crack, which are used to predict the contribution to the out-of-plane displacement from the reflected and mode converted waves. This method has the potential to provide a reliable method for the near field identification and characterisation of surface breaking defects in plates

Signal enhancement of the in-plane and out-of-plane Rayleigh wave components

Several groups have reported an enhancement of the ultrasonic Rayleigh wave when scanning close to a surface-breaking defect in a metal sample. This enhancement may be explained as an interference effect where the waves passing directly between source and receiver interfere with those waves reflected back from the defect. We present finite element models of the predicted enhancement when approaching a defect, along with experiments performed using electromagnetic acoustic transducers sensitive to either in-plane or out-of-plane motion. A larger enhancement of the in-plane motion than the out-of-plane motion is observed and can be explained by considering ultrasonic reflections and mode conversion at the defect

Phased electromagnetic acoustic transducer array for Rayleigh wave surface defect detection

A phased electromagnetic acoustic transducer (EMAT) array system has been developed for detection and characterisation of surface breaking defects. An array of four linear coils which are individually controlled are used to generate a Rayleigh wave. The high current electronics combined with the coil designs enables the array to generate either narrowband or broadband signals, and controlling the phase delay between the channels makes it possible to change the ultrasound wavelength without requiring the physical separation of the coils to be changed. Experimental results show that the four-coil phased array is able to generate a wavelength range from 3.0 mm to 11.7 mm. Surface breaking defects were characterised using a transmit-receive set-up with a broadband EMAT detector being used to detect the Rayleigh wave. Machined surface slots with different depths were used for technique validation. The results show that the array is sensitive to surface defects and that a wide depth sensitivity range for defect sizing can be easily achieved by applying phasing to tune the wavelength of operation. A large increase in detection flexibility is immediately shown

The interaction of polymer dispersed liquid crystal sensors with ultrasound

Polymer dispersed liquid crystals (PDLCs) have been shown to be sensitive to ultrasound through the acousto-optic effect. The acousto-optic response of PDLCs was studied over a broad frequency range (0.3–10 MHz). We demonstrate that the displacements required to produce acousto-optic clearing of PDLC films can be as low as a few nanometers, which is at least 103 times smaller than the PDLC droplet size, is 105 times smaller than the PDLC layer thickness, and of the order of the molecular size of the liquid crystal constituents. This suggests that the acousto-optic effect in PDLCs is due to the microscopic effects of the LC reorientation under torques or flows rather than the LC reorientation through macroscopic droplet deformation. The displacement required for clearing is related to the frequency of operation via an exponential decay. We attribute the observed frequency response to a freezing out of the rotational motion around the short axis of the liquid crystal. The reported frequency dependence and displacements required indicate that the effects and materials described here could be used for ultrasound visualization in a non-destructive testing context

Scanning laser source and scanning laser detection techniques for different surface crack geometries

Standard test samples typically contain simulated defects such as slots machined normal to the surface. However, real defects will not always propagate in this manner; for example, rolling contact fatigue on rails propagates at around 25º to the surface, and corrosion cracking can grow in a branched manner. Therefore, there is a need to understand how ultrasonic surface waves interact with different crack geometries. We present measurements of machined slots inclined at an angle to the surface normal, or with simple branched geometries, using laser ultrasound. Recently, Rayleigh wave enhancements observed when using the scanning laser source technique, where a generation laser is scanned along a sample, have been highlighted for their potential in detecting surface cracks. We show that the enhancement measured with laser detector scanning can give a more significant enhancement when different crack geometries are considered. We discuss the behaviour of an incident Rayleigh wave in the region of an angled defect, and consider mode-conversions which lead to a very large enhancement when the detector is close to the opening of a shallow defect. This process could be used in characterising defects, as well as being an excellent fingerprint of their presence

Non-linear enhancement of laser generated ultrasonic Rayleigh waves by cracks

Laser generated ultrasound has been widely used for detecting cracks, surface and sub-surface defects in many different materials. It provides a non-contact wideband excitation source which can be focused into different geometries. Previous workers have reported enhancement of the laser generated Rayleigh wave when a crack is illuminated by pulsed laser beam irradiation. We demonstrate that the enhancement observed is due to a combination of source truncation, the free boundary condition at the edge of the crack and interference effects. Generating a Rayleigh wave over a crack can lead to enhancement of the amplitude of the Rayleigh wave signal, a shift in the dominant frequency of the wideband Rayleigh wave and strong enhancement of the high frequency components of the Rayleigh wave

Non-contact ultrasonic detection of angled surface defects

Non-destructive testing is an important technique, and improvements are constantly needed. Surface defects in metals are not necessarily confined to orientations normal to the sample surface; however, much of the previous work investigating the interaction of ultrasonic surface waves with surface-breaking defects has assumed cracks inclined at 90° to the surface. This paper explores the interaction of Rayleigh waves with cracks which have a wide range of angles and depths relative to the surface, using a non-contact laser generation and detection system. Additional insight is acquired using a 3D model generated using finite element method software. A clear variation of the reflection and transmission coefficients with both crack angle and length is found, in both the out-of-plane and in-plane components. The 3D model is further used to understand the contributions of different wavemodes to B-Scans produced when scanning a sample, to enable understanding of the reflection and transmission behaviour, and help identify angled defects. Knowledge of these effects is essential to correctly gauge the severity of surface cracking

Characterisation of hidden defects using the near-field ultrasonic enhancement of Lamb waves

Defects that propagate from the inside of a structure can be difficult to detect by traditional non-destructive inspection methods. A non-contact inspection method is presented here that uses the near-field interactions of ultrasonic Lamb waves to detect defects propagating into a 1.5 mm thick aluminium sheet from the opposite side to that which is inspected. Near-field interactions of the S0 Lamb waves with the defects are shown to give rise to a characteristic increase in the wave magnitude, which is used to position and characterise these hidden defects. It is shown that such defects are difficult to detect from a study of their influence on ultrasonic transmission alone. Single defects of different depths, and systems of multiple defects with varying separations and relative depths, are successfully detected in both experimental trials and FEM simulations. Reliable single defect detection is achieved for defects with a minimum depth of 30% of the plate thickness, and resolution of multiple defects is achieved for defect separations of 5 mm

Shear wave generation using a spiral electromagnetic acoustic transducer

A spiral electromagnetic acoustic transducer (EMAT) is efficient in eddy current generation and has been used for surface defect inspection using Rayleigh waves or thickness gauging based on plane waves in echo mode. Measured and calculated particle velocities and directivities are presented. It is found that the shear wave is not predominantly a plane wave. It has zero amplitude on the axis of the generation EMAT and has maximum amplitude at the critical angle. The shear wave could be used in the steel industry for both internal and surface defect inspections together with Rayleigh wave