Hwanjeong Cho

Structural health monitoring of fatigue crack growth in plate structures with ultrasonic guided waves

Fatigue crack growth in plate structures is monitored with ultrasonic guided waves generated from piezoelectric transducers. Cracks initiate in the vicinity of fastener holes due to cyclic in-plane loading. Ultrasonic guided waves that are partially obstructed by the fastener holes are investigated. Since fatigue crack growth increases the obstruction, these waves are effective for monitoring fatigue crack growth in a pitch-catch mode. The transmission coefficient (TC), which is defined essentially as the current-to-baseline amplitude ratio, and the transmission coefficient ratio (TCR), which is based on amplitude ratios from a single wave, are signal features used for crack characterization. The TCR is well suited for structural health monitoring. The excellent agreement between experimental results and finite element analysis of wave propagation corroborates the experiments. A sparse array of transducers is shown to effectively monitor a multifastener joint. The approach using obstructed ultrasonic guided waves has strong potential for prognostics-based structural health management due to the linear relationship between crack size and the TC.

Second harmonic generation in composites: Theoretical and numerical analyses

Second harmonic generation in a transversely isotropic plate and a symmetric compositelaminate is analyzed from a theoretical perspective. The strain energy function for a nonlinear elastic transversely isotropic material is expressed in terms of the five invariants of the Green-Lagrange strain tensor. Internal resonance conditions for the generation of cumulative second harmonics indicate that a cumulative second harmonic exists when the primary-secondary mode pair satisfies the phase matching and non-zero power flux criteria. In particular, for transversely isotropic plates, when the primary mode propagates along the material principal direction, only symmetric second harmonic Lamb-like wave modes can be cumulative. Also, when the primary wave propagates along other directions, only symmetric second harmonic modes can be generated. Additionally, for the case of symmetric compositelaminates, only symmetric modes can be generated as cumulative second harmonics regardless of the propagation direction of the primary mode. To validate the above theoretical predictions, finite element simulations were conducted for mode pairs that are: (i) phase matched but have zero power flux, (ii) not phase matched but have non-zero power flux, and (iii) internally resonant i.e., satisfying both phase matching and non-zero power flux criterion. The results obtained from the simulations corroborate the theoretical findings for both transversely isotropic plates and symmetric compositelaminates.

Selection of Shear Horizontal Wave Transducers for Robotic Nondestructive Inspection in Harsh Environments

Harsh environments and confined spaces require that nondestructive inspections be conducted with robotic systems. Ultrasonic guided waves are well suited for robotic systems because they can provide efficient volumetric coverage when inspecting for various types of damage, including cracks and corrosion. Shear horizontal guided waves are especially well suited for robotic inspection because they are sensitive to cracks oriented perpendicular or parallel to the wave propagation direction and can be generated with electromagnetic acoustic transducers (EMATs) and magnetostrictive transducers (MSTs). Both types of transducers are investigated for crack detection in a stainless steel plate. The MSTs require the robot to apply a compressive normal force that creates frictional force coupling. However, the coupling is observed to be very dependent upon surface roughness and surface debris. The EMATs are coupled through the Lorentz force and are thus noncontact, although they depend on the lift off between transducer and substrate. After comparing advantages and disadvantages of each transducer for robotic inspection the EMATs are selected for application to canisters that store used nuclear fuel.

FATIGUE CRACK GROWTH MONITORING OF AN ALUMINUM JOINT STRUCTURE

The detection, location, and sizing of a fatigue crack emanating from a fastener hole in an aluminum plate is investigated. Two linear arrays of surface mounted piezoelectric disk transducers send and receive ultrasonic guided waves that are transmitted, reflected, and scattered by both the joint geometry and the fatigue crack. A tomography algorithm is used to detect and locate the crack. Amplitude ratio and signal difference coefficients are explored as candidate features to size the crack, which is necessary for reliability and remaining life calculations. Both of these features are quite sensitive to fatigue crack lengths as small as 0.13 of the hole diameter.

A Guided Wave Sensor Enabling Simultaneous Wavenumber-Frequency Analysis for Both Lamb and Shear-Horizontal Waves

Guided waves in plate-like structures have been widely investigated for structural health monitoring. Lamb waves and shear horizontal (SH) waves, two commonly used types of waves in plates, provide different benefits for the detection of various types of defects and material degradation. However, there are few sensors that can detect both Lamb and SH waves and also resolve their modal content, namely the wavenumber-frequency spectrum. A sensor that can detect both waves is desirable to take full advantage of both types of waves in order to improve sensitivity to different discontinuity geometries. We demonstrate that polyvinylidene difluoride (PVDF) film provides the basis for a multi-element array sensor that detects both Lamb and SH waves and also measures their modal content, i.e., the wavenumber-frequency spectrum.

Electromagnetic Acoustic Transducers for Robotic Nondestructive Inspection in Harsh Environments

Elevated temperature, gamma radiation, and geometric constraints inside dry storage casks for spent nuclear fuel represent a harsh environment for nondestructive inspection of the cask and require that the inspection be conducted with a robotic system. Electromagnetic acoustic transducers (EMATs) using non-contact ultrasonic transduction based on the Lorentz force to excite/receive ultrasonic waves are suited for use in the robotic inspection. Periodic permanent magnet EMATs that actuate/receive shear horizontal guided waves are developed for application to robotic nondestructive inspection of stress corrosion cracks in the heat affected zone of welds in stainless steel dry storage canisters. The EMAT’s components are carefully selected in consideration of the inspection environment, and tested under elevated temperature and gamma radiation doses up to 177 °C and 5920 krad, respectively, to evaluate the performance of the EMATs under realistic environmental conditions. The effect of gamma radiation is minimal, but the EMAT’s performance is affected by temperatures above 121 °C due to the low Curie temperature of the magnets. Different magnets are needed to operate at 177 °C. The EMAT’s capability to detect notches is also evaluated from B-scan measurements on 304 stainless steel welded plate containing surface-breaking notches.

Effect of Load and Temperature Changes on Nonlinear Ultrasonic Measurements: Implications for SHM

Advances in ultrasonic guided waves make it possible to combine the penetration power of guided waves with the early damage detection capabilities of nonlinear ultrasound to interrogate a fairly large area. However, there is a need to re-examine the definition of the relative nonlinearity parameter in the context of SHM. It is known that the definition of the relative nonlinearity parameter relies on the amplitudes of the fundamental and higher harmonic modes and a change in any of these can affect the relative nonlinearity parameter. For SHM methodologies incorporating nonlinear ultrasound, factors such as transducer operating conditions and environmental effects come into play and may affect the nonlinearity parameter even without significant microstructural changes in the material being interrogated. To bridge this gap, the current study aims to investigate the effect of load and temperature changes on guided wave third harmonic generation from shear horizontal (SH) waves in aluminum plates. SH waves were excited using magnetostrictive transducers and third harmonic measurements were made under increasing static-tensile loads at constant temperature and increasing temperature under no load. The results obtained, along with the implications for SHM incorporating nonlinear ultrasound are discussed. doi: 10.12783/SHM2015/99

Remote detection of stress corrosion cracking: Surface composition and crack detection

Chloride induced stress corrosion cracking (SCC) of austenitic stainless steel is a potential issue in long term dry storage of spent nuclear fuel canisters. In order for SCC to occur there must be a corrosive environment, a susceptible material, and a driving force. Because it is likely that the material in the heat affected zone (HAZ) of welded stainless steel structures has been sensitized as a result of chromium depletion at the grain boundaries and a thermal residual stress driving force is likely present if solution annealing is not performed, two issues are critical. Is the environment corrosive, i.e., are chlorides present in solution on the surface? And then, are there cracks that could propagate? Remote detection of chlorides on the surface can be accomplished by laser induced breakdown spectroscopy (LIBS), while cracks can be detected by shear horizontal guided waves generated by electromagnetic acoustic transducers (EMATs). Both are noncontact methods that are amenable to robotic delivery systems and harsh environments. The sensitivity to chlorine on stainless steel of a LIBS system that employs optical fiber for pulse delivery is demonstrated. Likewise, the ability of the EMAT system to detect cracks of a prescribed size and orientation is shown. These results show the potential for remote detection of Cl and cracks in dry storage spent fuel canisters.Chloride induced stress corrosion cracking (SCC) of austenitic stainless steel is a potential issue in long term dry storage of spent nuclear fuel canisters. In order for SCC to occur there must be a corrosive environment, a susceptible material, and a driving force. Because it is likely that the material in the heat affected zone (HAZ) of welded stainless steel structures has been sensitized as a result of chromium depletion at the grain boundaries and a thermal residual stress driving force is likely present if solution annealing is not performed, two issues are critical. Is the environment corrosive, i.e., are chlorides present in solution on the surface? And then, are there cracks that could propagate? Remote detection of chlorides on the surface can be accomplished by laser induced breakdown spectroscopy (LIBS), while cracks can be detected by shear horizontal guided waves generated by electromagnetic acoustic transducers (EMATs). Both are noncontact methods that are amenable to robotic delivery syst...

Effect of Skew Angle on Second Harmonic Guided Wave Measurement in Composite Plates

Waves propagating in anisotropic media are subject to skewing effects due to the media having directional wave speed dependence, which is characterized by slowness curves. Likewise, the generation of second harmonics is sensitive to micro-scale damage that is generally not detectable from linear features of ultrasonic waves. Here, the effect of skew angle on second harmonic guided wave measurement in a transversely isotropic lamina and a quasi-isotropic laminate are numerically studied. The strain energy density function for a nonlinear transversely isotropic material is formulated in terms of the Green-Lagrange strain invariants. The guided wave mode pairs for cumulative second harmonic generation in the plate are selected in accordance with the internal resonance criteria – i.e., phase matching and non-zero power flux. Moreover, the skew angle dispersion curves for the mode pairs are obtained from the semi-analytical finite element method using the derivative of the slowness curve. The skew angles of th...

Electromagnetic acoustic transducers for nondestructive inspection of dry storage canisters for used nuclear fuel

Inspection for stress corrosion cracking in stainless steel canisters that store used nuclear fuel must be done within a harsh environment that requires robotic delivery of the sensing system. The system must tolerate high temperatures and radiation and it must operate in constrained spaces. In order to be delivered robotically noncontact transducers are preferred. Electromagnetic acoustic transducers (EMATs) are noncontact transducers that can be made from materials capable of resisting high temperature and radiation and therefore are an excellent choice for this application. This presentation will describe the requirements of the dry storage environment, the ability of compact EMATs to detect cracks oriented both transverse and parallel to the wave vector using shear horizontal guided waves, and the nondestructive inspection methodology developed for full penetration weld regions. Laboratory experiments indicate that the pulse-echo mode is effective at detecting crack-like notches. B-scans constructed f...