Paul Fromme

On the development and testing of a guided ultrasonic wave array for structural integrity monitoring

The prototype of a guided ultrasonic wave array for the structural integrity monitoring of large, plate-like structures has been designed, built, and tested. The development of suitably small transducers for the excitation and measurement of the first antisymmetric Lamb wave mode A/sub 0/ is described. The array design consists of a ring of 32 transducers, permanently bonded to the structure with a protective membrane, in a compact housing with the necessary multiplexing electronics. Using a phased addition algorithm with dispersion compensation and deconvolution in the wavenumber domain, a good dynamic range can be achieved with a limited number of transducers. Limitations in the transducer design and manufacture restricted the overall dynamic range achieved to 27 dB. Laboratory measurements for a steel plate containing various defects have been performed. The results for standard defects are compared to theoretical predictions and the sensitivity of the array device for defect detection has been established. Simulated corrosion pitting and a defect cut with an angle grinder simulating general corrosion were detected.

Measurement of the scattering of a Lamb wave by a through hole in a plate

Flexural waves propagating in an aluminum plate containing a circular hole are studied. In the experiments the first antisymmetric Lamb wave mode A0 is excited selectively by a piezoelectric transducer. The scattered field around a circular cavity is measured pointwise using a heterodyne laser interferometer. The measurements are compared with theoretical calculations. Different approximate analytical approaches, employing Kirchhoff and Mindlin types of plate theories to describe the scattered field, are used. Good agreement between the experimental data and the analytical solutions is found within the ranges of validity of the different models. Introduction of a small imperfection, like a notch, at the boundary of the cavity changes the measured scattered field

Fatigue crack growth monitoring using high-frequency guided waves

A common problem in aircraft maintenance is the development of fatigue cracks at fastener holes due to stress concentration. High-frequency guided ultrasonic waves allow for the structural health monitoring of critical areas of a structure and can be measured with high accuracy using a noncontact laser interferometer. The use of a specific type of high-frequency guided ultrasonic wave that has good sensitivity for the detection of small defects, excited using a standard Rayleigh wedge transducer and propagating along the structure, has been investigated. Fatigue crack growth at the side of a fastener hole in a tensile, aluminum specimen was induced by cyclic loading of the structure. The crack length was monitored optically and showed good correlation with fracture mechanics calculations of the expected growth rate. The changes in the guided wave signal due to the fatigue damage were monitored using a noncontact laser interferometer and quantified. The measurements show a good sensitivity for the early detection of fatigue damage and for the monitoring of fatigue crack growth at a fastener hole. The propagation and scattering of the high-frequency guided ultrasonic wave has been simulated numerically using a three-dimensional finite difference code. Good agreement was found between the measured and predicted changes of the ultrasonic signal for the increasing fatigue crack area, allowing in principle for the approximate sizing of the defect.

High-frequency guided ultrasonic waves for hidden defect detection in multi-layered aircraft structures

Aerospace structures often contain multi-layered metallic components where hidden defects such as fatigue cracks and localized disbonds can develop, necessitating non-destructive testing. Employing standard wedge transducers, high frequency guided ultrasonic waves that penetrate through the complete thickness were generated in a model structure consisting of two adhesively bonded aluminium plates. Interference occurs between the wave modes during propagation along the structure, resulting in a frequency dependent variation of the energy through the thickness with distance. The wave propagation along the specimen was measured experimentally using a laser interferometer. Good agreement with theoretical predictions and two-dimensional finite element simulations was found. Significant propagation distance with a strong, non-dispersive main wave pulse was achieved. The interaction of the high frequency guided ultrasonic waves with small notches in the aluminium layer facing the sealant and on the bottom surface of the multilayer structure was investigated. Standard pulse-echo measurements were conducted to verify the detection sensitivity and the influence of the stand-off distance predicted from the finite element simulations. The results demonstrated the potential of high frequency guided waves for hidden defect detection at critical and difficult to access locations in aerospace structures from a stand-off distance.

On the reflection of coupled Rayleigh-like waves at surface defects in plates

The reflection of coupled Rayleigh-like waves from surface defects in elastic plates is investigated experimentally and analyzed on the basis of an analytical model and finite difference simulations. The propagation of Rayleigh-like waves in plates is characterized by an energy transfer to the opposite plate side and back over a distance called the beat length. Experimental results clearly show this beating effect and its dependency on the frequency-thickness product, and excellent agreement is obtained with existing analytical predictions. The propagation and scattering are modeled separately for the fundamental A(0) and S(0) Lamb modes that constitute the incident Rayleigh-like wave. The reflection coefficients from surface slots are investigated using finite difference simulations and the reflected Rayleigh-like wave is obtained by superposition. The theoretical model reveals strong dependencies of the reflected field on the ratio between excitation distance and beat length and on the cutoff frequencies of specific higher Lamb modes. Standard pulse-echo measurements allow for the detection of small defects from a remote transducer location. Good agreement is obtained between the predicted and measured amplitude spectra of the reflected Rayleigh-like wave. The developed model allows for the evaluation of defect location and damaged plate side using a combination of time-of-flight and frequency measurements.

High frequency guided ultrasonic waves for hidden fatigue crack growth monitoring in multi-layer model aerospace structures

Especially for ageing aircraft the development of fatigue cracks at fastener holes due to stress concentration and varying loading conditions constitutes a significant maintenance problem. High frequency guided waves offer a potential compromise between the capabilities of local bulk ultrasonic measurements with proven defect detection sensitivity and the large area coverage of lower frequency guided ultrasonic waves. High frequency guided waves have energy distributed through all layers of the specimen thickness, allowing in principle hidden (2nd layer) fatigue damage monitoring. For the integration into structural health monitoring systems the sensitivity for the detection of hidden fatigue damage in inaccessible locations of the multi-layered components from a stand-off distance has to be ascertained. The multi-layered model structure investigated consists of two aluminium plate-strips with an epoxy sealant layer. During cyclic loading fatigue crack growth at a fastener hole was monitored. Specific guided wave modes (combination of fundamental A0 and S0 Lamb modes) were selectively excited above the cut-off frequencies of higher modes using a standard ultrasonic wedge transducer. Non-contact laser measurements close to the defect were performed to qualify the influence of a fatigue crack in one aluminium layer on the guided wave scattering. Fatigue crack growth monitoring using laser interferometry showed good sensitivity and repeatability for the reliable detection of small, quarter-elliptical cracks. Standard ultrasonic pulse-echo equipment was employed to monitor hidden fatigue damage from a stand-off distance without access to the damaged specimen layer. Sufficient sensitivity for the detection of fatigue cracks located in the inaccessible aluminium layer was verified, allowing in principle practical in situ ultrasonic monitoring of fatigue crack growth.

Scattering of guided waves at delaminations in composite plates

Carbon fiber laminate composites are increasingly employed for aerospace structures as they offer advantages, such as a good strength to weight ratio. However, impact during the operation and servicing of the aircraft can lead to barely visible and difficult to detect damage. Depending on the severity of the impact, fiber and matrix breakage or delaminations can occur, reducing the load carrying capacity of the structure. Efficient nondestructive testing and structural health monitoring of composite panels can be achieved using guided ultrasonic waves propagating along the structure. The scattering of the A0 Lamb wave mode at delaminations was investigated using a full three-dimensional (3D) finite element (FE) analysis. The influence of the delamination geometry (size and depth) was systematically evaluated. In addition to the depth dependency, a significant influence of the delamination width due to sideways reflection of the guided waves within the delamination area was found. Mixed-mode defects were simulated using a combined model of delamination with localized material degradation. The guided wave scattering at cross-ply composite plates with impact damage was measured experimentally using a non-contact laser interferometer. Good agreement between experiments and FE predictions using the mixed-mode model for an approximation of the impact damage was found.

Influence of guided ultrasonic wave scattering directionality on the detection sensitivity for SHM of fatigue cracks

Localized and distributed guided ultrasonic waves array systems offer an efficient way for the long-term monitoring of the structural integrity for large structures. The use of permanently attached sensor arrays has been shown to be applicable to detect simulated corrosion damage. However, the detection sensitivity for fatigue cracks depends on the location and orientation of the crack relative to the transducer elements, and for some transducer locations no change in the signal even for a significant defect will be detected. Crack-like defects have a directionality pattern of the scattered field depending on the angle of the incident wave relative to the defect, the defect depth, and the ratio of the characteristic defect size to wavelength. The directionality pattern of the scattered field for the A0 Lamb wave mode is predicted from 3D Finite Element simulations and verified from experimental measurements at machined part-through and through-thickness notches using a laser interferometer. Good agreement is found and the directionality pattern can be predicted accurately. These results provide the basis for the quantification of the detection sensitivity for defects in plate structures using guided wave sensors.

Stray Current Corrosion and Mitigation: A synopsis of the technical methods used in dc transit systems.

Stray-current corrosion has been a source of concern for the transit authorities and utility companies since the inception of the electrified rail transit system. The corrosion problem caused by stray current was noticed within ten years of the first dc-powered rail line in the United States in 1888 [1] in Richmond, Virginia, and ever since, the control of stray current has been a critical issue. Similarly, the effects of rail and utility-pipe corrosion caused by stray current had been observed in Europe.

On the sensitivity of corrosion and fatigue damage detection using guided ultrasonic waves

Constant, long-time monitoring of large plate-like structures, e.g., oil storage tanks, can be performed using permanently attached remote sensors. A guided ultrasonic wave array consisting of piezoelectric transducer elements for the excitation and reception of the first antisymmetric Lamb wave mode A0, has been designed and built. Laboratory measurements for a steel plate containing various defects have been performed. The results are compared to theoretical predictions and the sensitivity of the array device for defect detection is ascertained.