Katherine M. M. Tant

A model-based approach to crack sizing with ultrasonic arrays

Ultrasonic phased array systems have become increasingly popular in the last 10 years as tools for flaw detection and characterization within the nondestructive testing industry. The existence and location of flaws can often be deduced via images generated from the data captured by these arrays. A factor common to these imaging techniques is the subjective thresholding required to estimate the size of the flaw. This paper puts forward an objective approach which employs a mathematical model. By exploiting the relationship between the width of the central lobe of the scattering matrix and the crack size, an analytical expression for the crack length is reached via the Born approximation. Conclusions are then drawn on the minimum resolvable crack length of the method and it is thus shown that the formula holds for subwavelength defects. An analytical expression for the error that arises from the discrete nature of the array is then derived and it is observed that the method becomes less sensitive to the discretization of the array as the distance between the flaw and array increases. The methodology is then extended and tested on experimental data collected from welded austenitic plates containing a lack-of-fusion crack of 6 mm length. An objective sizing matrix (OSM) is produced by assessing the similarity between the scattering matrices arising from experimentally collected data with those arising from the Born approximation over a range of crack lengths and frequencies. Initially, the global minimum of the OSM is taken as the objective estimation of the crack size, giving a measurement of 7 mm. This is improved upon by the adoption of a multifrequency averaging approach, with which an improved crack size estimation of 6.4 mm is obtained.

The detection of flaws in austenitic welds using the decomposition of the time reversal operator

The non-destructive testing of austenitic welds using ultrasound plays an important role in the assessment of the structural integrity of safety critical structures. The internal microstructure of these welds is highly scattering and can lead to the obscuration of defects when investigated by traditional imaging algorithms. This paper proposes an alternative objective method for the detection of flaws embedded in austenitic welds based on the singular value decomposition of the time-frequency domain response matrices. The distribution of the singular values is examined in the cases where a flaw exists and where there is no flaw present. A lower threshold on the singular values, specific to austenitic welds, is derived which, when exceeded, indicates the presence of a flaw. The detection criterion is successfully implemented on both synthetic and experimental data. The datasets arising from welds containing a flaw are further interrogated using the decomposition of the time-reversal operator (DORT) method and the total focusing method (TFM), and it is shown that images constructed via the DORT algorithm typically exhibit a higher signal-to-noise ratio than those constructed by the TFM algorithm.

A fractional Fourier transform analysis of the scattering of ultrasonic waves

Many safety critical structures, such as those found in nuclear plants, oil pipelines and in the aerospace industry, rely on key components that are constructed from heterogeneous materials. Ultrasonic non-destructive testing (NDT) uses high-frequency mechanical waves to inspect these parts, ensuring they operate reliably without compromising their integrity. It is possible to employ mathematical models to develop a deeper understanding of the acquired ultrasonic data and enhance defect imaging algorithms. In this paper, a model for the scattering of ultrasonic waves by a crack is derived in the time–frequency domain. The fractional Fourier transform (FrFT) is applied to an inhomogeneous wave equation where the forcing function is prescribed as a linear chirp, modulated by a Gaussian envelope. The homogeneous solution is found via the Born approximation which encapsulates information regarding the flaw geometry. The inhomogeneous solution is obtained via the inverse Fourier transform of a Gaussian-windowed linear chirp excitation. It is observed that, although the scattering profile of the flaw does not change, it is amplified. Thus, the theory demonstrates the enhanced signal-to-noise ratio permitted by the use of coded excitation, as well as establishing a time–frequency domain framework to assist in flaw identification and classification.

Mapping the material microstructure of safety critical components using ultrasonic phased arrays

Traditional imaging algorithms within the ultrasonic NDE community typically assume that the material being inspected is homogeneous. Obviously, when the medium is of a heterogeneous or anisotropic nature this assumption can contribute to the poor detection, sizing and characterisation of defects. Knowledge of the internal structure and properties of the material would allow corrective measures to be taken. The work presented here endeavours to reconstruct coarsened maps of the locally anisotropic grain structure of industrially representative samples from ultrasonic phased array data. This is achieved via application of the reversible-jump Markov Chain Monte Carlo (rj-MCMC) method: an ensemble approach within a Bayesian framework. The resulting maps are used in conjunction with the total focussing method and the reconstructed flaws are used as a quantitative measure of the success of this methodology. Using full matrix capture data arising from a finite element simulation of a phased array inspection of an austenitic weld, a 71% improvement in flaw location and an 11dB improvement in SNR is achieved using no a priori knowledge of the materials internal structure.

A spectral method for sizing cracks using ultrasonic arrays

Ultrasonic phased array systems are becoming increasingly popular as tools for the inspection of safety-critical structures within the non-destructive evaluation industry. The data-sets captured by these arrays can be used to image the internal structure of individual components, allowing the location and nature of any defects to be deduced. Although there exist strict procedures for measuring defects via these imaging algorithms, sizing flaws which are smaller than two wavelengths in diameter can prove problematic and the choice of threshold at which the defect measurements are made can introduce an aspect of subjectivity. This paper puts forward a completely objective approach specific to cracks based on the Kirchhoff scattering model and the approximation of the resulting scattering matrices by Toeplitz matrices. A mathematical expression relating the crack size to the maximum eigenvalue of the associated scattering matrix is derived. Analysis of this approximation shows that the method will provide a unique crack size for a given maximum eigenvalue whilst providing a quick calculation method which avoids the need to numerically generate model scattering matrices (the computation time is up to times faster). A sensitivity analysis demonstrates that the method is most effective for sizing defects that are commensurate with or smaller than the wavelength of the ultrasonic wave. The method is applied to simulated FMC data arising from finite element calculations where the crack length to wavelength ratios range between 0.6 and 1.9. The recovered objective crack size exhibits an error of 12%.

Application of the factorisation method to limited aperture ultrasonic phased array data

This paper puts forward a methodology for applying the frequency domain Factorisation Method to time domain experimental data arising from ultrasonic phased array inspections in a limited aperture setting. Application to both synthetic and experimental data is undertaken and a multi-frequency approach is explored to address the difficulty encountered in empirically choosing the optimum frequency at which to operate. Additionally, a truncated singular value decomposition (TSVD) approach is implemented in the case where the flaw is embedded in a highly scattering medium, to regularise the scattering matrix and minimise the contribution of microstructural noise to the final image. It is shown that when the Factorisation Method is applied to multi-frequency scattering matrices, it can better characterise crack-like scatterers than in the case where the data arises from a single frequency. Finally, a volumetric defect and a lack-of-fusion crack are both successfully reconstructed from experimental data, where the resulting images exhibit only 3\% and 10\% errors respectively in their measurement.

Finite element analysis simulations for ultrasonic array NDE inspections

Advances in manufacturing techniques and materials have led to an increase in the demand for reliable and robust inspection techniques to maintain safety critical features. The application of modelling methods to develop and evaluate inspections is becoming an essential tool for the NDE community. Current analytical methods are inadequate for simulation of arbitrary components and heterogeneous materials, such as anisotropic welds or composite structures. Finite element analysis software (FEA), such as PZFlex, can provide the ability to simulate the inspection of these arrangements, providing the ability to economically prototype and evaluate improved NDE methods. FEA is often seen as computationally expensive for ultrasound problems however, advances in computing power have made it a more viable tool. This paper aims to illustrate the capability of appropriate FEA to produce accurate simulations of ultrasonic array inspections – minimizing the requirement for expensive test-piece fabrication. Validation is afforded via corroboration of the FE derived and experimentally generated data sets for a test-block comprising 1D and 2D defects. The modelling approach is extended to consider the more troublesome aspects of heterogeneous materials where defect dimensions can be of the same length scale as the grain structure. The model is used to facilitate the implementation of new ultrasonic array inspection methods for such materials. This is exemplified by considering the simulation of ultrasonic NDE in a weld structure in order to assess new approaches to imaging such structures.