Francesco Ciampa

Impact detection in anisotropic materials using a time reversal approach

This article presents an in situ imaging method able to detect in real-time the impact source location in reverberant complex composite structures using only one passive sensor. This technique is based on the time reversal acoustic method applied to a number of waveforms stored in a database containing the impulse response (Green’s function) of the structure. The proposed method allows achieving the optimal focalization of the acoustic emission source in the time and spatial domain as it overcomes the drawbacks of other ultrasonic techniques. This is mainly due to the dispersive nature of guided Lamb waves as well as the presence of multiple scattering and mode conversion that can degrade the quality of the focusing, causing poor localization. Conversely, using the benefits of a diffuse wave field, the imaging of the source location can be obtained through a virtual time reversal procedure, which does not require any iterative algorithms and a priori knowledge of the mechanical properties and the anisotropic group speed. The efficiency of this method is experimentally demonstrated on a stiffened composite panel. The results showed that the impact source location can be retrieved with a high level of accuracy in any position of the structure (maximum error was less than 3%).

Acoustic emission source localization and velocity determination of the fundamental mode A0 using wavelet analysis and a Newton-based optimization technique

This paper investigates the development of an in situ impact detection monitoring system able to identify in real-time the acoustic emission location. The proposed algorithm is based on the differences of stress waves measured by surface-bonded piezoelectric transducers. A joint time-frequency analysis based on the magnitude of the continuous wavelet transform was used to determine the time of arrival of the wavepackets. A combination of unconstrained optimization technique associated with a local Newtons iterative method was employed to solve a set of nonlinear equations in order to assess the impact location coordinates and the wave speed. With the proposed approach, the drawbacks of a triangulation method in terms of estimating a priori the group velocity and the need to find the best time-frequency technique for the time-of-arrival determination were overcome. Moreover, this algorithm proved to be very robust since it was able to converge from almost any guess point and required little computational time. A comparison between the theoretical and experimental results carried out with piezoelectric film (PVDF) and acoustic emission transducers showed that the impact source location and the wave velocity were predicted with reasonable accuracy. In particular, the maximum error in estimation of the impact location was less than 2% and about 1% for the flexural wave velocity.

Impact localization in composite structures of arbitrary cross section

This article proposes an in situ structural health monitoring method able to locate the impact source and to determine the flexural Lamb mode A0 velocity in composite structures with unknown lay-up and cross section. The algorithm is based on the differences of the stress waves measured by six surface-attached acoustic emission piezoelectric (lead zirconate titanate) sensors and is branched off into two steps. In the first step, the magnitude of the squared modulus of continuous wavelet transform, which guarantees high accuracy in the time–frequency analysis of the acoustic waves, was used to identify the time of arrival of the flexural Lamb wave. Then, the coordinates of the impact location and the group speed values are obtained by solving a set of non-linear equations through a combination of local Newton’s iterative method associated with line search and polynomial backtracking techniques. The proposed method, in contrast to the current impact localization algorithms, does not require a priori knowledge of the anisotropy angular-group velocity pattern of the measured waveforms as well as the mechanical properties of the structure. To validate this method, experimental location testing was conducted on two different composite structures: a quasi-isotropic carbon fibre–reinforced plastic laminate and a sandwich panel. The results showed that source location was achieved with satisfactory accuracy (maximum error in estimation of the impact location was approximately 3 mm for quasi-isotropic carbon fibre–reinforced plastic panel and nearly 2 mm for sandwich plate), requiring little computational time (nearly 1 s). In addition, the values of the fundamental flexural Lamb mode A0 obtained from the optimization algorithm were compared with those determined by a numerical spectral finite element method.

Multifunctional SMArt composite material for in situ NDT/SHM and de-icing

The past few decades have seen significant growth in the development and application of multifunctional media for the enhancement of material properties, thermo-mechanical and sensing properties. This research work reports a novel approach in which a multifunctional material, herein referred to as SMArt composite, can be employed as a structural health monitoring system for strain sensing and damage detection (SMArt sensing and SMArt thermography), but also as an embedded ice protection tool for structural applications (referred as SMArt de-icing). Such a material, obtained by embedding shape memory alloy (SMA) wires within traditional carbon reinforced plastic composites, relies on the possibility of using the wires both to increase the mechanical properties of composites panels and to exploit their intrinsic electrothermal properties. The electrical resistance variation and the internal power resistive heating source provided by the SMA network, enable a built in and fast assessment of the strain distribution and in situ damage visualization via thermographic imaging. The efficiency of these techniques was experimentally validated on a number of SMArt composite laminates with single and multiple internal defects at various depths. The results showed that strain sensing and damage detection were achieved with high spatial resolution and accuracy, without the need to use large external heaters or complex signal processing techniques.

Nonlinear elastic wave tomography for the imaging of corrosion damage

This paper presents a nonlinear elastic wave tomography method, based on ultrasonic guided waves, for the image of nonlinear signatures in the dynamic response of a damaged isotropic structure. The proposed technique relies on a combination of high order statistics and a radial basis function approach. The bicoherence of ultrasonic waveforms originated by a harmonic excitation was used to characterise the second order nonlinear signature contained in the measured signals due to the presence of surface corrosion. Then, a radial basis function interpolation was employed to achieve an effective visualisation of the damage over the panel using only a limited number of receiver sensors. The robustness of the proposed nonlinear imaging method was experimentally demonstrated on a damaged 2024 aluminium panel, and the nonlinear source location was detected with a high level of accuracy, even with few receiving elements. Compared to five standard ultrasonic imaging methods, this nonlinear tomography technique does not require any baseline with the undamaged structure for the evaluation of the corrosion damage, nor a priori knowledge of the mechanical properties of the specimen.

Modelling of multiscale nonlinear interaction of elastic waves with three-dimensional cracks

This paper presents a nonlinear elastic material model able to simulate the nonlinear effects generated by the interaction of acoustic/ultrasonic waves with damage precursors and micro-cracks in a variety of materials. Such a constitutive model is implemented in an in-house finite element code and exhibits a multiscale nature where the macroscopic behavior of damaged structures can be represented through a contribution of a number of mesoscopic elements, which are composed by a statistical collection of microscopic units. By means of the semi-analytical Landau formulation and Preisach-Mayergoyz space representation, this multiscale model allows the description of the structural response under continuous harmonic excitation of micro-damaged materials showing both anharmonic and dissipative hysteretic effects. In this manner, nonlinear effects observed experimentally, such as the generation of both even and odd harmonics, can be reproduced. In addition, by using Kelvin eigentensors and eigenelastic constants, the wave propagation problem in both isotropic and orthotropic solids was extended to the three-dimensional Cartesian space. The developed model has been verified for a number of different geometrical and material configurations. Particularly, the influence of a small region with classical and non-classical elasticity and the variations of the input amplitudes on the harmonics generation were analyzed.

Nonlinear damage detection in composite structures using bispectral analysis

Literature offers a quantitative number of diagnostic methods that can continuously provide detailed information of the material defects and damages in aerospace and civil engineering applications. Indeed, low velocity impact damages can considerably degrade the integrity of structural components and, if not detected, they can result in catastrophic failure conditions. This paper presents a nonlinear Structural Health Monitoring (SHM) method, based on ultrasonic guided waves (GW), for the detection of the nonlinear signature in a damaged composite structure. The proposed technique, based on a bispectral analysis of ultrasonic input waveforms, allows for the evaluation of the nonlinear response due to the presence of cracks and delaminations. Indeed, such a methodology was used to characterize the nonlinear behaviour of the structure, by exploiting the frequency mixing of the original waveform acquired from a sparse array of sensors. The robustness of bispectral analysis was experimentally demonstrated on a damaged carbon fibre reinforce plastic (CFRP) composite panel, and the nonlinear source was retrieved with a high level of accuracy. Unlike other linear and nonlinear ultrasonic methods for damage detection, this methodology does not require any baseline with the undamaged structure for the evaluation of the nonlinear source, nor a priori knowledge of the mechanical properties of the specimen. Moreover, bispectral analysis can be considered as a nonlinear elastic wave spectroscopy (NEWS) technique for materials showing either classical or non-classical nonlinear behaviour.

Recent Advances in Active Infrared Thermography for Non-Destructive Testing of Aerospace Components

Active infrared thermography is a fast and accurate non-destructive evaluation technique that is of particular relevance to the aerospace industry for the inspection of aircraft and helicopters’ primary and secondary structures, aero-engine parts, spacecraft components and its subsystems. This review provides an exhaustive summary of most recent active thermographic methods used for aerospace applications according to their physical principle and thermal excitation sources. Besides traditional optically stimulated thermography, which uses external optical radiation such as flashes, heaters and laser systems, novel hybrid thermographic techniques are also investigated. These include ultrasonic stimulated thermography, which uses ultrasonic waves and the local damage resonance effect to enhance the reliability and sensitivity to micro-cracks, eddy current stimulated thermography, which uses cost-effective eddy current excitation to generate induction heating, and microwave thermography, which uses electromagnetic radiation at the microwave frequency bands to provide rapid detection of cracks and delamination. All these techniques are here analysed and numerous examples are provided for different damage scenarios and aerospace components in order to identify the strength and limitations of each thermographic technique. Moreover, alternative strategies to current external thermal excitation sources, here named as material-based thermography methods, are examined in this paper. These novel thermographic techniques rely on thermoresistive internal heating and offer a fast, low power, accurate and reliable assessment of damage in aerospace composites.

Impact localization on a composite tail rotor blade using an inverse filtering approach

This article presents an in situ structural health monitoring imaging system for the localization of impacts on a composite complex structure such as a tail rotor blade. Unlike conventional plate-like panels, this composite structure presents a strong anisotropy and inhomogeneous elastic nature due to the presence of both glass fibre and carbon fibre, a geometrically complex shape due to the curvature of the blade’s airfoil section and variations in the mechanical behaviour due to local changes in the thickness. The proposed imaging technique is based on the inverse filtering or reciprocal time reversal approach applied to the waveforms originated from a point of the structure of unknown location (impact source) and a number of signals stored in a database containing the experimental Green’s function of the medium. Unlike other ultrasonic impact localization methods, the present technique allows achieving the optimal focalization of the impact point in the spatial and time domain, by taking advantage of multiple linear scattering and a small number of receiver sensors.

On the generation of nonlinear damage resonance intermodulation for elastic wave spectroscopy

Recent nonlinear elastic wave spectroscopy experiments have shown that the nonlinear ultrasonic response of damaged composite materials can be enhanced by higher vibrations at the local damage resonance. In this paper, the mathematical formulation for the generation of nonlinear wave effects associated with continuous periodic excitation and the concept of local defect resonance is provided. Under the assumption of both quadratic and cubic approximation, the existence of higher harmonics of the excitation frequency, superharmonics of the damage resonance frequency and nonlinear wave effects, here named as nonlinear damage resonance intermodulation, which correspond to the nonlinear intermodulation between the driving and the damage resonance frequencies, is proved. All these nonlinear elastic effects are caused by the interaction of propagating ultrasonic waves with the local damage resonance and can be measured at locations different from the material defect one. The proposed analytical model is confirmed and validated through experimental transducer-based measurements of the steady-state nonlinear resonance response on a damaged composite sample. These results will provide opportunities for early detection and imaging of material flaws.