Design and Manufacture of an Optimised Side-Shifted PPM EMAT Array for Use in Mobile Robotic Localisation.

Guided wave Electro Magnetic Acoustic Transducers (EMATs) offer an elegant method for structural inspection and localisation relative to geometric features, such as welds. This paper presents a Lorentz force EMAT construction framework, where a numerical model has been developed for optimising Printed Circuit Board (PCB) coil parameters as well as a methodology for optimising magnet array parameters to a user's needs. This framework was validated experimentally to show its effectiveness through comparison to an industry built EMAT. The framework was then used to design and manufacture a Side-Shifted Unidirectional Periodic Permanent Magnet (PPM) EMAT for use on a mobile robotic system, which uses guided waves for ranging to build internal maps of a given subject, identifying welded sections, defects and other structural elements. The unidirectional transducer setup was shown to operate in simulation and was then manufactured to compare to the bidirectional transmitter and two-receiver configurations on a localisation system. The unidirectional setup was shown to have clear benefits over the bidirectional setup for mapping an unknown environment using guided waves as there were no dead spots of mapping where signal direction could not be interpreted. Additionally, overall package size was significantly reduced, which in turn allows more measurements to be taken within confined spaces and increases robotic crawler mobility.

Single-mode Lamb wave excitation at high-frequency-thickness products using a conventional linear array transducer.

Lamb wave excitation at high-frequency-thickness products offers a potential solution for high-resolution guided wave testing. The method is attractive for crack imaging and corrosion mapping, especially in hidden locations where direct access is limited. However, multiple modes may propagate, complicating signal interpretation, which is undesirable. In this work, a systematic approach is presented, in an effort to determine the influence of the key parameters related to single higher order Lamb wave mode excitation using a conventional linear array transducer. Specifically, a linear time delay law is used to enhance the targeted mode, while the array's length, pitch and apodisation profile remain to be optimally selected. First, an analytical solution is derived based on modal analysis. This provides a natural decomposition of the amplitude of a guided wave mode into the product of the response of a single element and the excitation spectrum. Then, a key observation is made, associating the excitation spectrum to the directivity function for bulk wave phased array steering. This allows the application of well-established phased array analysis tools to guided wave phased array excitation. In light of this fact, minimisation of the spectrum's bandwidth, elimination of the grating lobes and derivation of an apodisation profile are performed, to enhance the purity of the targeted mode. Finally, experiments conducted on an aluminium plate verify the above theoretical results. The Full Matrix is acquired, and all signals are reconstructed synthetically.

Applying a nonlinear, pitch-catch, ultrasonic technique for the detection of kissing bonds in friction stir welds.

Friction stir welding (FSW) is a promising technology for the joining of aluminum alloys and other metallic admixtures that are hard to weld by conventional fusion welding. Although FSW generally provides better fatigue properties than traditional fusion welding methods, fatigue properties are still significantly lower than for the base material. Apart from voids, kissing bonds for instance, in the form of closed cracks propagating along the interface of the stirred and heat affected zone, are inherent features of the weld and can be considered as one of the main causes of a reduced fatigue life of FSW in comparison to the base material. The main problem with kissing bond defects in FSW, is that they currently are very difficult to detect using existing NDT methods. Besides, in most cases, the defects are not directly accessible from the exposed surface. Therefore, new techniques capable of detecting small kissing bond flaws need to be introduced. In the present paper, a novel and practical approach is introduced based on a nonlinear, single-sided, ultrasonic technique. The proposed inspection technique uses two single element transducers, with the first transducer transmitting an ultrasonic signal that focuses the ultrasonic waves at the bottom side of the sample where cracks are most likely to occur. The large amount of energy at the focus activates the kissing bond, resulting in the generation of nonlinear features in the wave propagation. These nonlinear features are then captured by the second transducer operating in pitch-catch mode, and are analyzed, using pulse inversion, to reveal the presence of a defect. The performance of the proposed nonlinear, pitch-catch technique, is first illustrated using a numerical study of an aluminum sample containing simple, vertically oriented, incipient cracks. Later, the proposed technique is also applied experimentally on a real-life friction stir welded butt joint containing a kissing bond flaw.

Linear and Nonlinear Guided Wave Imaging of Impact Damage in CFRP Using a Probabilistic Approach.

The amount and variety of composite structures that need to be inspected for the presence of impact damage has grown significantly in the last few decades. In this paper, an application of a probabilistic ultrasonic guided wave imaging technique for impact damage detection in carbon fiber-reinforced polymers (CFRP) is presented. On the one hand, a linear, baseline-dependent, technique utilizing the well-known correlation-based RAPID method and an array of piezoelectric transducers is applied to detect impact-induced damage in plate-like composite structures. Furthermore, a baseline-independent nonlinear extension of the standard RAPID method is proposed, and its performance is demonstrated both numerically and experimentally. Compared to the conventional RAPID, the baseline-free version suffers from a somewhat lower imaging quality. However, this drawback is compensated by the fact that no damage-free (intact) baseline is necessary for successful imaging of damage.