Sputtered ZnO film on aluminium foils for flexible ultrasonic transducers.

Nanocrystalline ZnO films with both C-axis vertical grown and inclined angled grown were sputter-deposited onto aluminium foils (50 µm thick) and characterised for using as flexible ultrasonic transducers. As-deposited C-axis grown ZnO films were annealed at different temperatures up to 600 °C to enhance film crystallinity and reduce film stress. The C-axis grown ZnO film on the Al foil were bonded onto steel plates, and the pulse-echo tests verified a good performance (with dominant longitudinal waves) of the ultrasonic transducers made from both as-deposited and post-annealed films. Inclined angled ZnO films on the Al foil glued onto steel plates generated mixed shear and longitudinal waves in the pulse-echo test.

Annealing effect on the generation of dual mode acoustic waves in inclined ZnO films.

ZnO films with different inclined angles on steel substrates were sputter-deposited by changing the substrate tilt angle during deposition and then used to fabricate ZnO film ultrasonic transducers. The ultrasonic performance of those devices was characterized using a standard pulse-echo method. A dual mode wave with both longitudinal and shear wave components was detected from the ZnO device at 0° inclined angle. At a columnar inclined angle of 31°, longitudinal wave excitation was suppressed with a nearly pure shear wave detected. Post annealing of the ZnO film improved the crystallinity and decreased the film stress. The dispersion of the received echoes was observed when the grain sizes of ZnO films were increased after annealing. The frequency components of the waveforms were analyzed and identified using a short time Fourier transform. Post-annealing of the ZnO films changed the primary frequency and enhanced the propagation of the relative high-frequency acoustic wave.

Experimental and simulated performance of lithium niobate 1-3 piezocomposites for 2 MHz non-destructive testing applications.

Lithium niobate piezocomposites have been investigated as the active element in high temperature resistant ultrasonic transducers for non-destructive testing applications up to 400°C. Compared to a single piece of lithium niobate crystal they demonstrate shorter pulse length by 3×, elimination of lateral modes, and resistance to cracking. In a 1-3 connectivity piezocomposite for high temperature use (200-400°C), lithium niobate pillars are embedded in a matrix of flexible high temperature sealant or high temperature cement. In order to better understand the design principles and constraints for use of lithium niobate in piezocomposites experiments and modelling have been carried out. For this work the lithium niobate piezocomposites were investigated at room temperature so epoxy filler was used. 1-3 connectivity piezocomposite samples were prepared with z-cut lithium niobate, pillar width 0.3-0.6mm, sample thickness 1-4mm, pillar aspect ratio (pillar height/width) 3-6, volume fraction 30 and 45%. Operating frequency was 1-2MHz. Experimental measurements of impedance magnitude and resonance frequency were compared with 3-D finite element modelling using PZFlex. Resonance frequencies were predicted within 0.05MHz and impedance magnitude within 2-5% for samples with pillar aspect ratio ≥3 for 45% volume fraction and pillar aspect ratio ⩾6 for 30% volume fraction. Laser vibrometry of pulse excitation of piezocomposite samples in air showed that the lithium niobate pillars and the epoxy filler moved in phase. Experiment and simulation showed that the thickness mode coupling coefficient k(t) of the piezocomposite was maintained at the lithium niobate bulk value of approximately 0.2 down to a volume fraction of 30%, consistent with calculations using the (Smith and Auld, 1991) model for piezocomposites.

1-3 connectivity lithium niobate composites for high temperature operation.

Lithium niobate, LiNbO(3), is a piezoelectric material well known for its high Curie temperature. However, it has often been neglected for use in ultrasonic transducers because of its low electro-mechanical coupling coefficients. Recent advances in signal processing have made this disadvantage less significant and we now report an investigation of the potential of LiNbO(3) composites for use in high temperature transducers for non-destructive testing (NDT). LiNbO(3) composites of 1-3 connectivity in room temperature vulcanising (RTV) sealant and cement matrices were fabricated by the dice and fill method. The RTV and the cement are specified to withstand temperatures up to 350 degrees C and 1600 degrees C, respectively. The composites have been characterized by electrical impedance measurement at ambient and elevated temperatures. In array configuration, transmit-receive signals from the back wall of a steel specimen were obtained at room temperature with good signal to noise ratio. High temperature measurements were made at temperatures up to 180 degrees C for the RTV composite and 360 degrees C for the cement composite configured as single element transducers. Temperature cycling has also been investigated and the new composite materials have been demonstrated to withstand several cycles without deterioration. It is concluded that they may contribute toward a solution to presently unsolved problems in NDT at elevated temperatures.

Imaging with lithium niobate/epoxy composites.

Lithium niobate, LiNbO3, is a very promising material for high temperature applications in non-destructive testing because of its high Curie temperature. However, for commercial applications LiNbO3 has often been neglected because of its low electromechanical coupling coefficients. This paper explores the potential of LiNbO3 composites, by means of room temperature characterization and measurements, for further use in operation in high temperature transducers. LiNbO3 composites of 1-3 connectivity in an epoxy matrix with volume fractions of LiNbO3 of 33% and 54% were fabricated. The composites were characterized by electrical impedance measurements and the results were compared with modelled impedance characteristics. Many parameters were predicted accurately, including an improvement of more than 75% in thickness mode electromechanical coupling coefficient, from kT=0.17 for bulk LiNbO3 to kT=0.32 for composite material. Some large discrepancies between simulation and experiment were also identified when a conventional one-dimensional model was used to calculate equivalent composite material parameters; however, finite element modelling was more accurate. After characterization, the composite was configured for use as a linear array. Functional measurements were conducted on steel blocks with a side drilled hole to represent a crack tip. This was detected by the array and visualized in time-of-flight diffraction B-scan images.

1-3 connectivity piezoelectric ceramic-polymer composite transducers made with viscous polymer processing for high frequency ultrasound.

Potential applications of high frequency ultrasound exist because of the high spatial resolution consequent upon short wavelength. The frequencies of interest, typically from 25 MHz upwards, are easily supported by modern instrumentation but the capabilities of ultrasonic transducers have not kept pace and the transducers in high frequency commercial ultrasonic systems are still made with single-phase crystal, ceramic or piezopolymer materials. Despite potential performance advantages, the 1-3 connectivity piezoelectric ceramic-polymer composite materials now widely used at lower ultrasonic frequencies have not been adopted because of manufacturing difficulties. These difficulties are centred on fabrication of the 1-3 piezoceramic bristle-block comprising tall, thin pillars upstanding from a supporting stock. Fabrication techniques which have been explored already include injection moulding, mechanical dicing, and laser machining. Here, we describe an alternative technique based on viscous polymer processing (VPP) to produce net shape ceramic bristle-blocks. VPP produces green-state ceramic with rheological properties suitable for embossing. We outline how this can be created then report on our work to fabricate PZT bristle-blocks with lateral pillar dimensions of the order of 50 microm and height-to-width ratios of the order of 10. These have been backfilled with low pre-cure viscosity polymer and made into complete 1-3 piezocomposite transducer elements. We outline the performance of the transducers in terms of electrical impedance and pulse-echo behaviour and show that it corresponds well with computer modelling. We conclude that VPP is a promising technique to allow the established advantages of piezocomposite material to be exploited at higher frequencies than have been possible so far.

Thick aluminium nitride films deposited by room-temperature sputtering for ultrasonic applications.

Materials in film form for electromechanical transduction have a number of potential applications in ultrasound. They are presently under investigation in flexural transducers for air-coupled ultrasound and underwater sonar operating at frequencies up to a few megahertz. At higher frequencies, they have the potential to be integrated with electronics for applications of ultrasound requiring high spatial resolution. However, a number of fabrication difficulties have arisen in studies of such films. These include the high temperatures required in many thick and thin film deposition processes, making them incompatible with other stages in transducer fabrication, and difficulties maintaining film quality when thin film--typically sub-1 microm--processes are extended to higher thicknesses. In this paper, we first outline a process which has allowed us to deposit aluminium nitride (AlN) films capable of electromechanical transduction at thicknesses up to more than 5 microm without substrate heating. As an ultrasonic transduction material, AlN has functional disadvantages, particularly a high acoustic velocity and weak electromechanical transduction. However, it also has a number of advantages relating to practicality of fabrication and functionality. These include the ability to be deposited on a variety of amorphous substrates, a very high Curie temperature, low permittivity, and low electrical and mechanical losses. Here, we present experimental results highlighting the transduction capabilities of AlN deposited on aluminium electrodes on glass and lithium niobate. We compare the results with those from standard simulation processes, highlighting the reasons for discrepancies and discussing the implications for incorporation of AlN into standard ultrasonic transducer design processes.

1-3 connectivity composite material made from lithium niobate and cement for ultrasonic condition monitoring at elevated temperatures.

We have designed, manufactured and tested a piezoelectric composite material to operate at temperatures above 400 degrees C. The material is a 1-3 connectivity composite with pillars of Z-cut lithium niobate in a matrix of alumina cement. The composite material produced shorter pulses than a monolithic plate of lithium niobate and remained intact upon cooling. Results are presented from room temperature and high temperature testing. This material could be bonded permanently to a test object, making it possible to carry out condition monitoring over an extended period. A new excitation method was also developed to enable remote switching between array elements.

Ultrasonic arrays for monitoring cracks in an industrial plant at high temperatures.

A piezoelectric linear array structure has been designed to operate at temperatures up to 400 degrees C for nondestructive testing of steel components of a hot industrial plant. It is intended that these arrays be fixed permanently to the test subject so that known defects can be monitored by comparing measurements taken over a period of time without needing to shut down the plant. The arrays are used in pairs: the transmitter is a phased array producing a variable angle steered beam, and a second array is used for receiving. The defect can be identified from a series of scans collected from individual elements of the second array. A simple monolithic array structure was used, based on a single crystal of lithium niobate and operating in the frequency range 3 to 5 MHz. Prototype devices have 64 elements on a 0.5 mm pitch. Simulated defects in steel blocks have been scanned at high temperatures to illustrate the arrays' capability for nondestructive testing. The results suggest an accuracy better than 1 mm in finding the location of crack tips.