Reliability Analysis of PAUT Based on the Round-Robin Test for Pipe Welds with Thermal Fatigue Cracks.

Thermal fatigue cracks occurring in pipes in nuclear power plants pose a high degree of risk. Thermal fatigue cracks are generated when the thermal fatigue load caused by local temperature gradients is repeatedly applied. The flaws are mainly found in welds, owing to the effects of stress concentration caused by the material properties and geometric shapes of welds. Thermal fatigue pipes are classified as targets of risk-informed in-service inspection, for which ultrasonic testing, a volumetric non-destructive testing method, is applied. With the advancement of ultrasonic testing techniques, various studies have been conducted recently to apply the phased array ultrasonic testing (PAUT) method to the inspection of thermal fatigue cracks occurring on pipes. A quantitative reliability analysis of the PAUT method must be performed to apply the PAUT method to on-site thermal fatigue crack inspection. In this study, to evaluate the quantitative reliability of the PAUT method for thermal fatigue cracks, we fabricated crack specimens with the thermal fatigue mechanism applied to the pipe welds. We performed a round-robin test to collect PAUT data and determine the validity of the detection performance (probability of detection; POD) and the error in the sizing accuracy (root-mean-square error; RMSE) evaluation. The analysis results of the POD and sizing performance of the length and depth of thermal fatigue cracks were comparatively evaluated with the acceptance criteria of the American Society of Mechanical Engineers Code to confirm the effectiveness of applying the PAUT method.

Through-Silicon via Device Non-Destructive Defect Evaluation Using Ultra-High-Resolution Acoustic Microscopy System.

In this study, an ultra-high-resolution acoustic microscopy system capable of non-destructively evaluating defects that may occur in thin film structures was fabricated. It is an integrated system of the control module, activation module, and data acquisition system, in which an integrated control software for controlling each module was developed. The control module includes the mechanical, control, and ultrasonic parts. The activation module was composed of the pulser/receiver, and the data acquisition system included an A/D board. In addition, the integrated control software performs system operation and material measurement and includes an analysis program to analyze the obtained A-Scan signals in various ways. A through-silicon via (TSV) device, which is a semiconductor structure, was prepared to verify the performance of the developed system. The TSV device was analyzed using an ultra-high-resolution acoustic microscope. When the C-Scan images were analyzed, void defects with a size of 20 µm were detected at a depth of approximately 32.5 µm. A similar result could be confirmed when the cross section was measured using focused ion beam (FIB) microscopy.

Evaluation of Adhesion Properties of Thin Film Structure through Surface Acoustic Wave Dispersion Simulation.

A theoretical simulation study of the dispersion characteristic of the surface acoustic wave (Rayleigh wave) was conducted by modeling the adhesion interlayer with stiffness coefficients to evaluate the bonding properties of nano-scale thin film structures. For experimental validation, a set of thin film specimens were fabricated-637 nm, 628 nm, 637 nm, 600 nm, and 600 nm thick titanium (Ti) films were deposited on silicon (Si) (100) substrate using a DC Magnetron sputtering process with DC power from 28.8 W, 57.6 W, 86.4 W, 115.2 W, and 144 W. The thicknesses of the Ti films were measured using a scanning electron microscope (SEM). Surface acoustic wave velocity for each of the manufactured thin film specimens was measured by using a V(z) curve technique of a Scanning Acoustic Microscope. The measured velocity, transducer frequency, and thickness of the film were applied to dispersion characteristic simulation for a given stiffness coefficient to calculate adhesion strength of each specimen. To verify the simulation result, the adhesion force of each specimen was measured using a nano-scratch test and then compared with the calculated values from the dispersion characteristic simulation. The value of adhesion strength from the dispersion characteristic simulation and the value of adhesion force of the nano-scratch test were found to have a similar tendency according to the process variable of the thin film. The results demonstrated that the adhesion strength of a thin film could be evaluated quantitatively by calculating the dispersion characteristics with the adhesion interlayer stiffness model.

Development of a High-Resolution Acoustic Sensor Based on ZnO Film Deposited by the RF Magnetron Sputtering Method.

In the study, an acoustic sensor for a high-resolution acoustic microscope was fabricated using zinc oxide (ZnO) piezoelectric ceramics. The c-cut sapphire was processed into a lens shape to deposit a ZnO film using radio frequency (RF) magnetron sputtering, and an upper and a lower electrode were deposited using E-beam evaporation. The electrode was a Au thin film, and a Ti thin film was used as an adhesion layer. The surface microstructure of the ZnO film was observed using a scanning electron microscope (SEM), the thickness of the film was measured using a focused ion beam (FIB) for piezoelectric ceramics deposited on the sapphire wafer, and the thickness of ZnO was measured to be 4.87 µm. As a result of analyzing the crystal growth plane using X-ray diffraction (XRD) analysis, it was confirmed that the piezoelectric characteristics were grown to the (0002) plane. The sensor fabricated in this study had a center frequency of 352 MHz. The bandwidth indicates the range of upper (375 MHz) and lower (328 MHz) frequencies at the -6 dB level of the center frequency. As a result of image analysis using the resolution chart, the resolution was about 1 µm.

Analysis of Flaw Detection Sensitivity of Phased Array Ultrasonics in Austenitic Steel Welds According to Inspection Conditions.

The anisotropy and inhomogeneity exhibited by austenitic steel in welds poses a challenge to nondestructive testing employing ultrasonic waves, which is predominantly utilized for the inspection of welds in power plants. In this study, we assess the reliability of phased array ultrasonic testing (PAUT) by analyzing the flaw detection sensitivity of ultrasonic beams in anisotropic welds, based on the inspection conditions. First, we simulated the sectorial scan technique, frequently employed for the inspection of actual welds, while taking into account the ultrasonic wave mode, frequency, and shape and position of a flaw. Subsequently, we analyzed the flaw sensitivity by comparing A-scan signals and S-scan results. The sensitivity analysis results confirmed the detection of all flaws by considering at least two inspection methods based on the shape and position of the flaw. Furthermore, we verified our model by performing an experiment under the same conditions as the simulation and found that the results were in agreement. Hence, we find that the simulation modeling technique proposed in this study can be utilized to develop suitable inspection conditions, according to the flaw characteristics or inspection environment.

Optimal Design of Annular Phased Array Transducers for Material Nonlinearity Determination in Pulse-Echo Ultrasonic Testing.

Nonlinear ultrasound has been proven to be a useful nondestructive testing tool for micro-damage inspection of materials and structures operating in harsh environment. When measuring the nonlinear second harmonic wave in a solid specimen in the pulse-echo (PE) testing mode, the stress-free boundary characteristics brings the received second harmonic component close to zero. Therefore, the PE method has never been employed to measure the so-called "nonlinear parameter (ß)", which is used to quantify the degree of micro-damage. When there are stress-free boundaries, a focused beam is known to improve the PE reception of the second harmonic wave, so phased-array (PA) transducers can be used to generate the focused beam. For the practical application of PE nonlinear ultrasonic testing, however, it is necessary to develop a new type of PA transducer that is completely different from conventional ones. In this paper, we propose a new annular PA transducer capable of measuring ß with improved second harmonic reception in the PE mode. Basically, the annular PA transducer (APAT) consists of four external ring transmitters and an internal disk receiver at the center. The focused beam properties of the transducers are analyzed using a nonlinear sound beam model which incorporates the effects of beam diffraction, material attenuation, and boundary reflection. The optimal design of the APAT is performed in terms of the maximum second harmonic reception and the total correction close to one, and the results are presented in detail.

Evaluation of the adhesion on the nano-scaled polymeric film systems.

We applied scanning acoustic microscopy known as the V(z) curve technique to photoresist thin-film systems for the evaluation of the adhesive strength at the film-substrate interface. Through the measurement of the SAW (Surface Acoustic Wave) velocity, the V(z) curve analysis allows us to quantify the stiffness of the film-substrate interface. In addition, we conducted a nano-scratch test to quantify the ultimate strength of the adhesion through the evaluation of the critical load. To vary the adhesive conditions, we prepared thin-film specimens with three different types of pre-coating surface treatments, i.e., oxygen-plasma bombardment, HMDS (Hexametyldisilazane) treatment and untreated. The magnitudes of the quantified stiffness and ultimate strength are found consistent with each other for all the specimens tested, indicating that the pre-coating surface treatment can strengthen both the stiffness and ultimate strength of the adhesion. The results of this study demonstrate the usefulness of the V(Z) analysis as a nondestructive method to evaluate the adhesion strength of nano-structured thin-film systems.

Evaluation of near-surface stress distributions in dissimilar welded joint by scanning acoustic microscopy.

This paper presents the results from a set of experiments designed to ultrasonically measure the near surface stresses distributed within a dissimilar metal welded plate. A scanning acoustic microscope (SAM), with a tone-burst ultrasonic wave frequency of 200 MHz, was used for the measurement of near surface stresses in the dissimilar welded plate between 304 stainless steel and low carbon steel. For quantitative data acquisition such as leaky surface acoustic wave (leaky SAW) velocity measurement, a point focus acoustic lens of frequency 200 MHz was used and the leaky SAW velocities within the specimen were precisely measured. The distributions of the surface acoustic wave velocities change according to the near-surface stresses within the joint. A three dimensional (3D) finite element simulation was carried out to predict numerically the stress distributions and compare with the experimental results. The experiment and FE simulation results for the dissimilar welded plate showed good agreement. This research demonstrates that a combination of FE simulation and ultrasonic stress measurements using SAW velocity distributions appear promising for determining welding residual stresses in dissimilar material joints.

Residual Stress Analysis Based on Acoustic and Optical Methods.

Co-application of acoustoelasticity and optical interferometry to residual stress analysis is discussed. The underlying idea is to combine the advantages of both methods. Acoustoelasticity is capable of evaluating a residual stress absolutely but it is a single point measurement. Optical interferometry is able to measure deformation yielding two-dimensional, full-field data, but it is not suitable for absolute evaluation of residual stresses. By theoretically relating the deformation data to residual stresses, and calibrating it with absolute residual stress evaluated at a reference point, it is possible to measure residual stresses quantitatively, nondestructively and two-dimensionally. The feasibility of the idea has been tested with a butt-jointed dissimilar plate specimen. A steel plate 18.5 mm wide, 50 mm long and 3.37 mm thick is braze-jointed to a cemented carbide plate of the same dimension along the 18.5 mm-side. Acoustoelasticity evaluates the elastic modulus at reference points via acoustic velocity measurement. A tensile load is applied to the specimen at a constant pulling rate in a stress range substantially lower than the yield stress. Optical interferometry measures the resulting acceleration field. Based on the theory of harmonic oscillation, the acceleration field is correlated to compressive and tensile residual stresses qualitatively. The acoustic and optical results show reasonable agreement in the compressive and tensile residual stresses, indicating the feasibility of the idea.