Guided wave propagation and skew effects in anisotropic carbon fiber reinforced laminates.

Guided ultrasonic waves provide a promising structural health monitoring (SHM) solution for composite structures as they are able to propagate relatively long distances with low attenuation. However, the material anisotropy results in directionally dependent phase and group velocities, in addition to energy focusing, wave skewing, and beam spreading phenomena. These effects could lead to inaccurate damage localization if not accounted for. In this contribution, the guided wave propagation behavior (A0 mode) for a highly anisotropic, unidirectional carbon fiber reinforced polymer laminate is systematically investigated through both finite element analysis and non-contact laser measurements and compared to theoretical predictions. The directional dependency of phase and group velocity measured for a point and line source shows good agreement with theoretical predictions, once a correction for wave skew effects is applied. Wave skew angles were evaluated from the experimental and numerical wave propagation in multiple directions and matched theoretical predictions based on the phase slowness curve. Significant guided wave beam spreading from a line source was observed and quantified from both experiments and simulations and compared with theoretical predictions using the anisotropy factor. The impact of anisotropic guided wave propagation behavior on SHM is discussed.

Lamb wave propagation in monocrystalline silicon wafers.

Monocrystalline silicon wafers are widely used in the photovoltaic industry for solar panels with high conversion efficiency. Guided ultrasonic waves offer the potential to efficiently detect micro-cracks in the thin wafers. Previous studies of ultrasonic wave propagation in silicon focused on effects of material anisotropy on bulk ultrasonic waves, but the dependence of the wave propagation characteristics on the material anisotropy is not well understood for Lamb waves. The phase slowness and beam skewing of the two fundamental Lamb wave modes A0 and S0 were investigated. Experimental measurements using contact wedge transducer excitation and laser measurement were conducted. Good agreement was found between the theoretically calculated angular dependency of the phase slowness and measurements for different propagation directions relative to the crystal orientation. Significant wave skew and beam widening was observed experimentally due to the anisotropy, especially for the S0 mode. Explicit finite element simulations were conducted to visualize and quantify the guided wave beam skew. Good agreement was found for the A0 mode, but a systematic discrepancy was observed for the S0 mode. These effects need to be considered for the non-destructive testing of wafers using guided waves.

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.

Bone remodelling prediction using mechanical stimulus with bone connectivity theory in porous implants.

Strain energy density (SED) is considered to be the primary remodelling stimulus influencing the process of bone growth into porous implants. A bone remodelling algorithm incorporating the concept of bone connectivity, that newly formed bone should only grow from existing bone, was developed to provide a more biologically realistic simulation of bone growth. Results showed that the new algorithm prevented the occurrence of unconnected mature bone within porous implants, an unrealistic phenomenon observed using conventional adaptive elasticity theories. The bone connectivity algorithm had minimal effect (0.67% difference) on the final bone density distribution for standard bending and torsional moment cases. For a porous implant model, both algorithms, with and without bone connectivity implementation, reached the same final stiffness, with a difference of less than 0.01%. The bone connectivity algorithm predicted a slower and more gradual bone remodelling process, requiring at least 50% additional time for full remodelling compared to the conventional adaptive elasticity algorithm, which should be accounted for in the planning of rehabilitation strategies. The developed modelling can be employed to improve porous implant designs to achieve better clinical outcomes.

MET exon 14 skipping mutation is a hepatocyte growth factor (HGF)-dependent oncogenic driver in vitro and in humanised HGF knock-in mice.

Exon skipping mutations of the MET receptor tyrosine kinase (METex14), increasingly reported in cancers, occur in 3-4% of non-small-cell lung cancer (NSCLC). Only 50% of patients have a beneficial response to treatment with MET-tyrosine kinase inhibitors (TKIs), underlying the need to understand the mechanism of METex14 oncogenicity and sensitivity to TKIs. Whether METex14 is a driver mutation and whether it requires hepatocyte growth factor (HGF) for its oncogenicity in a range of in vitro functions and in vivo has not been fully elucidated from previous preclinical models. Using CRISPR/Cas9, we developed a METex14/WT isogenic model in nontransformed human lung cells and report that the METex14 single alteration was sufficient to drive MET-dependent in vitro anchorage-independent survival and motility and in vivo tumorigenesis, sensitising tumours to MET-TKIs. However, we also show that human HGF (hHGF) is required, as demonstrated in vivo using a humanised HGF knock-in strain of mice and further detected in tumour cells of METex14 NSCLC patient samples. Our results also suggest that METex14 oncogenicity is not a consequence of an escape from degradation in our cell model. Thus, we developed a valuable model for preclinical studies and present results that have potential clinical implication.

Individual variation in Achilles tendon morphology and geometry changes susceptibility to injury.

The unique structure of the Achilles tendon, combining three smaller sub-tendons, enhances movement efficiency by allowing individual control from connected muscles. This requires compliant interfaces between sub-tendons, but compliance decreases with age and may account for increased injury frequency. Current understanding of sub-tendon sliding and its role in the whole Achilles tendon function is limited. Here we show changing the degree of sliding greatly affects the tendon mechanical behaviour. Our in vitro testing discovered distinct sub-tendon mechanical properties in keeping with their mechanical demands. In silico study based on measured properties, subject-specific tendon geometry, and modified sliding capacity demonstrated age-related displacement reduction similar to our in vivo ultrasonography measurements. Peak stress magnitude and distribution within the whole Achilles tendon are affected by individual tendon geometries, the sliding capacity between sub-tendons, and different muscle loading conditions. These results suggest clinical possibilities to identify patients at risk and design personalised rehabilitation protocols.

Measurement of the temperature-dependent output of lead zirconate titanate transducers.

The effect of temperature and electrical drive conditions on the output of lead zirconate titanate (PZT) transducers is of particular interest in ultrasound metrology and medical ultrasound applications. In this work, the temperature-dependent output of two single-element PZT transducers was measured between 22 °C and 46 °C. Two independent measurement methods were used, namely radiation force balance measurements and laser vibrometry. When driven at constant voltage using a 50 Ω matched signal generator and amplifier using continuous wave (CW) or quasi-CW excitation, the output of the two transducers increased on average by 0.6 % per degree, largely due to an increase in transducer efficiency with temperature. The two measurement methods showed close agreement. Similar trends were observed when using single cycle excitation with the same signal chain. However, when driven using a pulser (which is not electrically matched), the two transducers exhibited different behaviour depending on their electrical impedance. Accounting for the temperature-dependent output of PZT transducers could have implications for many areas of ultrasound metrology, for example, in therapeutic ultrasound where a coupling fluid at an increased or decreased temperature is often used.

Partial Bone Formation in Additive Manufactured Porous Implants Reduces Predicted Stress and Danger of Fatigue Failure.

New porous implant designs made possible by additive manufacturing allow for increased osseointegration, potentially improving implant performance and longevity for patients that require massive bone implants. The aim of this study was to evaluate how implantation and the strain distribution in the implant affect the pattern of bone ingrowth and how changes in tissue density within the pores alter the stresses in implants. The hypothesis was that porous metal implants are susceptible to fatigue failure, and that this reduces as osteointegration occurs. A phenomenological, finite element analysis (FEA) bone remodelling model was used to predict partial bone formation for two porous (pore sizes of 700 µm and 1500 µm), laser sintered Ti6Al4V implants in an ovine condylar defect model, and was compared and verified against in vivo, histology results. The FEA models predicted partial bone formation within the porous implants, but over-estimated the amount of bone-surface area compared to histology results. The stress and strain in the implant and adjacent tissues were assessed before, during bone remodelling, and at equilibrium. Results showed that partial bone formation improves the stress distribution locally by reducing stress concentrations for both pore sizes, by at least 20%. This improves the long-term fatigue resistance for the larger pore implant, as excessively high stress is reduced to safer levels (86% of fatigue strength) as bone forms. The stress distribution only changed slightly in regions without bone growth. As the extent of bone formation into extensively porous bone implants depends on the level of stress shielding, the design of the implant and stiffness have significant influence on bone integration and need to be considered carefully to ensure the safety of implants with substantial porous regions. To our knowledge this is the first time that the effect of bone formation on stress distribution within a porous implant has been described and characterised.

The effect of strontium and silicon substituted hydroxyapatite electrochemical coatings on bone ingrowth and osseointegration of selective laser sintered porous metal implants.

Additive manufactured, porous bone implants have the potential to improve osseointegration and reduce failure rates of orthopaedic devices. Substantially porous implants are increasingly used in a number of orthopaedic applications. HA plasma spraying-a line of sight process-cannot coat the inner surfaces of substantially porous structures, whereas electrochemical deposition of calcium phosphate can fully coat the inner surfaces of porous implants for improved bioactivity, but the osseous response of different types of hydroxyapatite (HA) coatings with ionic substitutions has not been evaluated for implants in the same in vivo model. In this study, laser sintered Ti6Al4V implants with pore sizes of Ø 700 µm and Ø 1500 µm were electrochemically coated with HA, silicon-substituted HA (SiHA), and strontium-substituted HA (SrHA), and implanted in ovine femoral condylar defects. Implants were retrieved after 6 weeks and histological and histomorphometric evaluation were compared to electrochemically coated implants with uncoated and HA plasma sprayed controls. The HA, SiHA and SrHA coatings had Ca:P, Ca:(P+Si) and (Ca+Sr):P ratios of 1.53, 1.14 and 1.32 respectively. Electrochemically coated implants significantly promoted bone attachment to the implant surfaces of the inner pores and displayed improved osseointegration compared to uncoated scaffolds for both pore sizes (p<0.001), whereas bone ingrowth was restricted to the surface for HA plasma coated or uncoated implants. Electrochemically coated HA implants achieved the highest osseointegration, followed by SrHA coated implants, and both coatings exhibited significantly more bone growth than plasma sprayed groups (p≤0.01 for all 4 cases). SiHA had significantly more osseointegration when compared against the uncoated control, but no significant difference compared with other coatings. There was no significant difference in ingrowth or osseointegration between pore sizes, and the bone-implant-contact was significantly higher in the electrochemical HA than in SiHA or SrHA. These results suggest that osseointegration is insensitive to pore size, whereas surface modification through the presence of an osteoconductive coating plays an important role in improving osseointegration, which may be critically important for extensively porous implants.

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.

Novel adaptive finite element algorithms to predict bone ingrowth in additive manufactured porous implants.

Bone loss caused by stress shielding of metallic implants is a concern, as it can potentially lead to long-term implant failure. Surface coating and reducing structural stiffness of implants are two ways to improve bone ingrowth and osteointegration. Additive manufacturing, through selective laser sintering (SLS) or electron beam melting (EBM) of metallic alloys, can produce porous implants with bone ingrowth regions that enhance osteointegration and improve clinical outcomes. Histology of porous Ti6Al4V plugs of two pore sizes with and without electrochemically deposited hydroxyapatite coating, implanted in ovine condyles, showed that bone formation did not penetrate deep into the porous structure, whilst significantly increased bone growth along coated pore surfaces (osteointegration) was observed. Finite Element simulations, combining new algorithms to model bone ingrowth and the effect of surface modification on osteoconduction, were verified with the histology results. The results showed stress shielding of porous implants made from conventional titanium alloy due to material stiffness and implant geometry, limiting ingrowth and osteointegration. Simulations for reduced implant material stiffness predicted increased bone ingrowth. For low modulus Titanium-tantalum alloy (Ti-70%Ta), reduced stress shielding and enhanced bone ingrowth into the porous implant was found, leading to improved mechanical interlock. Algorithms predicted osteoconductive coating to promote both osteointegration and bone ingrowth into the inner pores when they were coated. These new Finite Element algorithms show that using implant materials with lower elastic modulus, osteoconductive coatings or improved implant design could lead to increased bone remodelling that optimises tissue regeneration, fulfilling the potential of enhanced porosity and complex implant designs made possible by additive layer manufacturing techniques.

A novel adaptive algorithm for 3D finite element analysis to model extracortical bone growth.

Extracortical bone growth with osseointegration of bone onto the shaft of massive bone tumour implants is an important clinical outcome for long-term implant survival. A new computational algorithm combining geometrical shape changes and bone adaptation in 3D Finite Element simulations has been developed, using a soft tissue envelope mesh, a novel concept of osteoconnectivity, and bone remodelling theory. The effects of varying the initial tissue density, spatial influence function and time step were investigated. The methodology demonstrated good correspondence to radiological results for a segmental prosthesis.

Analysis of high frequency guided wave scattering at a fastener hole with a view to fatigue crack detection.

The scattering of high frequency guided ultrasonic waves by a fatigue crack at the side of a fastener hole has been studied. The guided wave pulse consists of the superposition of the two fundamental Lamb modes A0 and S0 above the cut-off frequencies of the higher modes. The scattered field was simulated using a three-dimensional finite difference algorithm with a staggered, Cartesian grid for the limited area of interest around the hole and an analytical phase angle correction for the additional, variable propagation distance. Experimentally, the modes were selectively excited using a standard ultrasonic wedge transducer and measured using a laser interferometer, resulting in good spatial resolution. The scattered field was measured and simulated for an undamaged hole, a small, part-thickness quarter-elliptical fatigue crack, and a through-thickness fatigue crack. Good agreement was found and a significant influence of the fatigue cracks on the scattered field was observed. The complex difference of the scattered field due to additional scattered waves at the fatigue cracks of variable depth and length was evaluated. This allows for the prediction of high frequency guided wave sensitivity for fatigue crack detection at fastener holes, a significant maintenance problem for ageing aircraft.

The effect of bone growth onto massive prostheses collars in protecting the implant from fracture.

Limb-sparing distal femoral endoprotheses used in cancer patients have a high risk of aseptic loosening. It had been reported that young adolescent patients have a higher rate of loosening and fatigue fracture of intramedullary stems because the implant becomes undersized as patients grow. Extracortical bone growth into the grooved hydroxyapatite-coated collar had been shown to reduce failure rates. The stresses in the implant and femur have been calculated from Finite Element models for different stages of bone growth onto the collar. For a small diameter stem without any bone growth, a large stress concentration at the implant shoulder was found, leading to a significant fracture risk under normal walking loads. Bone growth and osseointergration onto the implant collar reduced the stress level in the implant to safe levels. For small bone bridges a risk of bone fracture was observed.

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 Ao 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.

The bending strength of tablets with a breaking line--Comparison of the results of an elastic and a "brittle cracking" finite element model with experimental findings.

The aim of this work was to ascertain the influence of the position of the breaking line of bevel-edged tablets in a three-point bending test. Two different brands of commercially available, flat-round, bevel-edged tablets with a single central breaking line were studied. Breaking line positions tested, relative to the upper loading roll, were 0°, 22.5°, 45°, 67.5° and 90°. The breaking line faced either up- or downwards during the test. The practical results were compared with FEM results simulating similar test configurations. Tablets failed mainly across the failure plane, resulting in two tablet halves. An exception to this was found for tablets where the breaking line faced down and was positioned at an angle of 22.5° relative to the loading plane. Here the crack followed the breaking line in the centre of the tablets and only diverged towards the loading plane position at the edges of the tablets. The breaking line facing upwards resulted in a significantly higher tensile strength of the tablets compared to it facing downwards. However, with one exception, the orientation of the breaking line relative to the loading plane appeared not to affect the tensile strength values. A fully elastic FEM model indicated that both the position of the breaking line relative to the loading plane and as to whether the breaking line faced up- or downwards during the bending test would result in considerably different failure loads during practical experiments. The results also suggested that regardless of the breaking line position, when it is facing down crack propagation should start at the outer edges propagating towards the midpoint of the discs until failure occurs. Failure should hence always result in equal tablet halves, whereby the failure plane should coincide with the loading plane. Neither predictions fully reflected the practical behaviour of the tablets. Using a brittle cracking FEM model significantly larger tensile stresses for tablets with the breaking line positioned downwards at 0° or 22.5° relative to the loading plane were still predicted, but the differences between model and experimental values was greatly reduced. The remaining differences are more likely due to the inadequacy of the equation available to calculate the experimental tensile strength values. This equation cannot account for the presence of a breaking line and overestimates the thickness of the loading plane by the depth of the breaking line when in 0° or 22.5° position. If the depth of the breaking line is taken into account, the model predictions and the experimental findings are comparable. Also, in the brittle cracking FEM simulations the predicted crack propagation patterns were similar to those found in the experiments, and the model stress distributions across the lower surfaces were much more homogeneous and streamlined parallel to the loading plane. The brittle cracking model hence reflected the practicalities of the bending test more closely. The findings suggested that with the breaking line facing down fracture should always start in the centre of a tablet at its lower surface, initiated by the breaking line. Due to simultaneous development of larger stresses along the y-axis the tablet should still break into two equal halves along the loading plane, unless the position of the breaking line relative to the loading plane was 22.5°. In this case the tablet would fail by a mixed process, whereby failure would occur mainly along the breaking line, but due to simultaneous crack formation at the lower surface close to the bevel edge parallel to the loading plane the final breaking pattern would deviate from the breaking line about half-way from its centre, as seen in the practical experiments.

Detection of cracks at rivet holes using guided waves.

Guided Lamb waves can be used for a fast inspection of large areas, e.g. the detection of cracks at rivet holes in the fuselage of airplanes. When the guided wave hits a discontinuity like a hole, a typical scattered displacement field is obtained. A change of the scattered field indicates the development of a crack. In the experiments, the first anti-symmetric mode A0 of Lamb waves in plates is excited selectively by means of a piezoelectric transducer. The used frequency range is below the cut-off frequencies of higher wave modes. The scattered field around undamaged and damaged holes is measured on a grid around the hole with a heterodyne laser interferometer. Two types of damage are introduced: a notch cut with a very fine saw blade, and a fatigue grown crack. A significant change in the scattered field due to the defect is seen. Good agreement of the experimental results with theoretical calculations is obtained. The wave propagation is studied using Mindlin's theory of plates. The scattered field is calculated analytically and using finite difference methods (FDMs).

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.

Theoretical investigations into the influence of the position of a breaking line on the tensile failure of flat, round, bevel-edged tablets using finite element methodology (FEM) and its practical relevance for industrial tablet strength testing.

Flat, round tablets may have a breaking ("score") line. Pharmacopoeial tablet breaking load tests are diametral in their design, and industrially used breaking load testers often have automatic tablet feeding systems, which position the tablets between the loading platens of the machine with the breaking lines in random orientation to the applied load. The aim of this work was to ascertain the influence of the position of the breaking line in a diametral compression test using finite element methodology (FEM) and to compare the theoretical results with practical findings using commercially produced bevel-edged, scored tablets. Breaking line test positions at an angle of 0°, 22.5°, 45°, 67.5° and 90° relative to the loading plane were studied. FEM results obtained for fully elastic and elasto-plastic tablets were fairly similar, but they highlighted large differences in stress distributions depending on the position of the breaking line. The stress values at failure were predicted to be similar for tablets tested at an angle of 45° or above, whereas at lower test angles the predicted breaking loads were up to three times larger. The stress distributions suggested that not all breaking line angles would result in clean tensile failure. Practical results, however, did not confirm the differences in the predicted breaking loads, but they confirmed differences in the way tablets broke. The results suggest that it is not advisable to convert breaking loads obtained on scored tablets into tablet tensile strength values, and comparisons between different tablets or batches should carefully consider the orientation of the breaking line with respect to the loading plane, as the failure mechanisms appear to vary.

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