Vykintas Samaitis

An Adjustment-Free NDT Technique for Defect Detection in Multilayered Composite Constructions Using Ultrasonic Guided Waves

In recent years, the novel lightweight honeycomb sandwich structures have been applied in a wide range of industries. However, daily operational conditions, fatigue, as well as various defects developed during exploitation lead to the risk of structure failure. To meet safety and economical requirements, such structures must be tested. In this paper, an ultrasonic pitchcatch technique based on ultrasonic guided waves (UGW) for detection of defects in honeycomb sandwich structures is proposed. The technique is based on simultaneous scanning of a pair of

Hybrid Signal Processing Technique to Improve the Defect Estimation in Ultrasonic Non-Destructive Testing of Composite Structures

This work proposes a novel hybrid signal processing technique to extract information on disbond-type defects from a single B-scan in the process of non-destructive testing (NDT) of glass fiber reinforced plastic (GFRP) material using ultrasonic guided waves (GW). The selected GFRP sample has been a segment of wind turbine blade, which possessed an aerodynamic shape. Two disbond type defects having diameters of 15 mm and 25 mm were artificially constructed on its trailing edge. The experiment has been performed using the low-frequency ultrasonic system developed at the Ultrasound Institute of Kaunas University of Technology and only one side of the sample was accessed. A special configuration of the transmitting and receiving transducers fixed on a movable panel with a separation distance of 50 mm was proposed for recording the ultrasonic guided wave signals at each one-millimeter step along the scanning distance up to 500 mm. Finally, the hybrid signal processing technique comprising the valuable features of the three most promising signal processing techniques: cross-correlation, wavelet transform, and Hilbert–Huang transform has been applied to the received signals for the extraction of defects information from a single B-scan image. The wavelet transform and cross-correlation techniques have been combined in order to extract the approximated size and location of the defects and measurements of time delays. Thereafter, Hilbert–Huang transform has been applied to the wavelet transformed signal to compare the variation of instantaneous frequencies and instantaneous amplitudes of the defect-free and defective signals.

Propagation of Ultrasonic Guided Waves in Composite Multi-Wire Ropes

Multi-wire ropes are widely used as load-carrying constructional elements in bridges, cranes, elevators, etc. Structural integrity of such ropes can be inspected by using non-destructive ultrasonic techniques. The objective of this work was to investigate propagation of ultrasonic guided waves (UGW) along composite multi-wire ropes in the cases of various types of acoustic contacts between neighboring wires and the plastic core. The modes of UGW propagating along the multi-wire ropes were identified using modelling, the dispersion curves were calculated using analytical and semi-analytical finite element (SAFE) techniques. In order to investigate the effects of UGW propagation, the two types of the acoustic contact between neighboring wires were simulated using the 3D finite element method (FE) as well. The key question of investigation was estimation of the actual boundary conditions between neighboring wires (solid or slip) and the real depth of penetration of UGW into the overall cross-section of the rope. Therefore, in order to verify the results of FE modelling, the guided wave penetration into strands of multi-wire rope was investigated experimentally. The performed modelling and experimental investigation enabled us to select optimal parameters of UGW to be used for non-destructive testing.

Analysis of Ultrasonic Guided Waves Propagation in Complex Composite Structures

The object of the investigation is a honeycomb structure of composite sandwich made of glass-epoxy laminating layers and a honeycomb core of epoxy impregnated paper. Large composite tanks possessing cylindrical shape are produced using the winding process. Therefore, the final products have uneven thickness and fibre orientation lamina layers, and also an unevenly impregnated honeycomb layer. The aim of this research is to develop an economically attractive embedded ultrasonic measurement technique for on-field diagnostics of complex composite structures used for production of large liquid storage tanks. Development of the relatively cheap and easy to operate embedded diagnostic/monitoring technique is important aiming to assure safety of liquid storage tanks (monitoring structural integrity against overpressure, etc.) and detection of accidental defects that may appear during transportation, installation and exploitation of those structures. Typical defects that are aimed to be detected are relatively large delaminations/disbonds (area having diameter of 150–200 mm) of skin layers caused by low energy impacts that cannot be detected visually and show severe influence on the structural strength and safety of liquid tanks. This work presents results of numerical modeling and experimental research in low frequency (50 kHz) ultrasonic guided waves (UGW) propagation in large honeycomb composite structures. Finite element (FE) simulation of UGW propagation has been made aiming to reduce quantity of ultrasonic transducers and optimize their placement on composite structure. The possibilities to place ultrasonic transducers and receivers on both sides (internal or external) of composite structures and to use such a proposed technique for detection of delamination/debonding areas caused by low energy impacts or alternating semi static loads (e.g. filling and draining of liquid from storage tank) and monitoring of partial self-healing of relatively rigid composite structures were proved by experimental testing.

2D Analytical Model for the Directivity Prediction of Ultrasonic Contact Type Transducers in the Generation of Guided Waves

In this paper, a novel 2D analytical model based on the Huygens’s principle of wave propagation is proposed in order to predict the directivity patterns of contact type ultrasonic transducers in the generation of guided waves (GWs). The developed model is able to estimate the directivity patterns at any distance, at any excitation frequency and for any configuration and shape of the transducers with prior information of phase dispersive characteristics of the guided wave modes and the behavior of transducer. This, in turn, facilitates to choose the appropriate transducer or arrays of transducers, suitable guided wave modes and excitation frequency for the nondestructive testing (NDT) and structural health monitoring (SHM) applications. The model is demonstrated for P1-type macro-fiber composite (MFC) transducer glued on a 2 mm thick aluminum (Al) alloy plate. The directivity patterns of MFC transducer in the generation of fundamental guided Lamb modes (the S0 and A0) and shear horizontal mode (the SH0) are successfully obtained at 80 kHz, 5-period excitation signal. The results are verified using 3D finite element (FE) modelling and experimental investigation. The results obtained using the proposed model shows the good agreement with those obtained using numerical simulations and experimental analysis. The calculation time using the analytical model was significantly shorter as compared to the time spent in experimental analysis and FE numerical modelling.

Influence of the Spatial Dimensions of Ultrasonic Transducers on the Frequency Spectrum of Guided Waves

Ultrasonic guided wave (UGW)-based condition monitoring has shown great promise in detecting, localizing, and characterizing damage in complex systems. However, the application of guided waves for damage detection is challenging due to the existence of multiple modes and dispersion. This results in distorted wave packets with limited resolution and the interference of multiple reflected modes. To develop reliable inspection systems, either the transducers have to be optimized to generate a desired single mode of guided waves with known dispersive properties, or the frequency responses of all modes present in the structure must be known to predict wave interaction. Currently, there is a lack of methods to predict the response spectrum of guided wave modes, especially in cases when multiple modes are being excited simultaneously. Such methods are of vital importance for further understanding wave propagation within the structures as well as wave-damage interaction. In this study, a novel method to predict the response spectrum of guided wave modes was proposed based on Fourier analysis of the particle velocity distribution on the excitation area. The method proposed in this study estimates an excitability function based on the spatial dimensions of the transducer, type of vibration, and dispersive properties of the medium. As a result, the response amplitude as a function of frequency for each guided wave mode present in the structure can be separately obtained. The method was validated with numerical simulations on the aluminum and glass fiber composite samples. The key findings showed that it can be applied to estimate the response spectrum of a guided wave mode on any type of material (either isotropic structures, or multi layered anisotropic composites) and under any type of excitation if the phase velocity dispersion curve and the particle velocity distribution of the wave source was known initially. Thus, the proposed method may be a beneficial tool to explain and predict the response spectrum of guided waves throughout the development of any structural health monitoring system.

3D Ultrasonic Non-destructive Evaluation of Spot Welds Using an Enhanced Total Focusing Method

Spot welds are used to join sheets of metals in the automotive industry. When spot weld quality is evaluated using conventional ultrasonic manual pulse-echo method, the reliability of the inspection is affected by selection of the probe diameter and the positioning of the probe in the weld center. The application of a 2D matrix array is a potential solution to the aforementioned problems. The objective of this work was to develop a signal processing algorithm to reconstruct the 3D spot weld volume showing the size of the nugget and the defects in it. In order to achieve this, the conventional total focusing method was enhanced by taking into account the directivities of the single elements of the array and the divergence of the ultrasonic beam due to the propagation distance. Enhancements enabled a reduction in the background noise and uniform sensitivity at different depths to be obtained. The proposed algorithm was verified using a finite element model of ultrasonic wave propagation simulating three common spot weld conditions: a good weld, an undersized weld, and a weld containing a pore. The investigations have demonstrated that proposed method enables the determination of the size of the nugget and detection of discontinuities.