Quantitative Detection of Pipeline Cracks Based on Ultrasonic Guided Waves and Convolutional Neural Network.

In this study, a quantitative detection method of pipeline cracks based on a one-dimensional convolutional neural network (1D-CNN) was developed using the time-domain signal of ultrasonic guided waves and the crack size of the pipeline as the input and output, respectively. Pipeline ultrasonic guided wave detection signals under different crack defect conditions were obtained via numerical simulations and experiments, and these signals were input as features into a multi-layer perceptron and one-dimensional convolutional neural network (1D-CNN) for training. The results revealed that the 1D-CNN performed better in the quantitative analysis of pipeline crack defects, with an error of less than 2% in the simulated and experimental data, and it could effectively evaluate the size of crack defects from the echo signals under different frequency excitations. Thus, by combining the ultrasonic guided wave detection technology and CNN, a quantitative analysis of pipeline crack defects can be effectively realized.

Mitigating the Impact of Temperature Variations on Ultrasonic Guided Wave-Based Structural Health Monitoring through Variational Autoencoders.

Structural health monitoring (SHM) has become paramount for developing cheaper and more reliable maintenance policies. The advantages coming from adopting such process have turned out to be particularly evident when dealing with plated structures. In this context, state-of-the-art methods are based on exciting and acquiring ultrasonic-guided waves through a permanently installed sensor network. A baseline is registered when the structure is healthy, and newly acquired signals are compared to it to detect, localize, and quantify damage. To this purpose, the performance of traditional methods has been overcome by data-driven approaches, which allow processing a larger amount of data without losing diagnostic information. However, to date, no diagnostic method can deal with varying environmental and operational conditions (EOCs). This work aims to present a proof-of-concept that state-of-the-art machine learning methods can be used for reducing the impact of EOCs on the performance of damage diagnosis methods. Generative artificial intelligence was leveraged to mitigate the impact of temperature variations on ultrasonic guided wave-based SHM. Specifically, variational autoencoders and singular value decomposition were combined to learn the influence of temperature on guided waves. After training, the generative part of the algorithm was used to reconstruct signals at new unseen temperatures. Moreover, a refined version of the algorithm called forced variational autoencoder was introduced to further improve the reconstruction capabilities. The accuracy of the proposed framework was demonstrated against real measurements on a composite plate.

A Multi-Strategy Hybrid Sparse Reconstruction Method Based on Spatial-Temporal Sparse Wave Number Analysis for Enhancing Pipe Ultrasonic-Guided Wave Anomaly Imaging.

Ultrasonic-guided waves (UGWs) in defective pipes are subject to severe coherent noise caused by imperfect detection conditions, mode conversion, and intrinsic characteristics (dispersion and multiple modes), inducing the limited performance of anomaly imaging. To achieve the high resolution and accuracy of anomaly imaging, a multi-strategy hybrid sparse reconstruction (MHSR) method based on spatial-temporal sparse wavenumber analysis (ST-SWA) is proposed. MHSR leverages the capability of ST-SWA to extract the wavenumber dispersion curves, thereby providing a more refined and precise search space for MHSR. Furthermore, it mitigates the impact of coherent noise by conducting dispersion compensation on the reconstructed signal. The sparse compensated signals through MHSR are employed for sparse reconstruction imaging. To validate the efficacy of the proposed method, UGW testing is performed on the defective steel pipe, and the results demonstrate the significant enhancement of anomaly imaging in defect resolution and positioning accuracy. The lowest estimated errors for axial and circumferential defect positions are 10 mm and 4 mm, respectively.

Explore Ultrasonic-Induced Mechanoluminescent Solutions towards Realising Remote Structural Health Monitoring.

Ultrasonic guided waves, which are often generated and detected by piezoelectric transducers, are well established to monitor engineering structures. Wireless solutions are sought to eliminate cumbersome wire installation. This work proposes a method for remote ultrasonic-based structural health monitoring (SHM) using mechanoluminescence (ML). Propagating guided waves transmitted by a piezoelectric transducer attached to a structure induce elastic deformation that can be captured by elastico-ML. An ML coating composed of copper-doped zinc sulfide (ZnS:Cu) particles embedded in PVDF on a thin aluminium plate can be used to achieve the elastico-ML for the remote sensing of propagating guided waves. The simulation and experimental results indicated that a very high voltage would be required to reach the threshold pressure applied to the ML particles, which is about 1.5 MPa for ZnS particles. The high voltage was estimated to be 214 Vpp for surface waves and 750 Vpp for Lamb waves for the studied configuration. Several possible technical solutions are suggested for achieving ultrasonic-induced ML for future remote SHM systems.

Reconstruction of Water-Filled Pipe Ultrasonic Guided Wave Signals in the Distance Domain by Orthogonal Matching Pursuit Based on Dispersion and Multi-Mode.

Ultrasonic guided waves (UGWs) in water-filled pipes are subject to more severe dispersion and attenuation than vacant pipes, posing significant challenges for defect identification and localization. To this end, a novel sparse signal decomposition method called orthogonal matching pursuit based on dispersion and multi-mode (DMOMP) was proposed, which utilizes the second-order asymptotic solution of dispersion curves and the conversion characteristics of asymmetric UGWs in the defect contact stage to reconstruct the dispersive signals and converts the time-domain dispersive signals to distance-domain non-dispersive signals by dispersion compensated time-distance mapping. The synthesized simulation results indicate that DMOMP not only exhibits higher reconstruction accuracy compared to OMP, but also reveals more accurate and stable mode recognition and localization compared to DOMP, which only considers the dispersion under perturbation and noise. In addition, the UGW testing experimental results of water-filled pipes verify the effectiveness of DMOMP, the localization accuracies of three feature signals (defct 1, defct 2 and end echo) with DMOMP are 99.10%, 98.72% and 98.36%, respectively, and the average localization accuracy of DMOMP is as high as 98.73%.

Multi-Order Mode Excitation and Separation of Ultrasonic Guided Waves in Rod Structures Using 2D-FFT.

The ultrasonic guided wave technique is extensively used for nondestructive structural testing, and one of the key steps is to extract a single mode with certain purity from multi-order mixed modes. In this paper, the propagation of ultrasonic guided waves in the cylindrical rod is simulated first; the appropriate broadband excitation signal is selected to excite the multi-order modes in a specific frequency range; and the time-space signal containing multi-order modes is converted to the frequency-wavenumber domain signal by two-dimensional Fourier transform. In the frequency-wavenumber domain, the frequency-wavenumber ridge is extracted from the multi-mode frequency-wavenumber domain based on the dynamic programming method, and then the time-domain signal corresponding to a single mode can be reconstructed. By comparing the excited multi-order mode and the separated single mode with the theoretical results, it is observed that the two results are consistent. Thus, the employed mode-excitation method can accurately excite the multi-order modes in rod structures. Furthermore, the proposed method enables the separation of a single-mode wave with high purity, providing a foundation for future utilization of isolated modes.

A New Method for Erosion Prediction of 90° Elbow Based on Non-Axisymmetric Ultrasonic-Guided Wave and the PSO-LSSVM Algorithm.

The non-axisymmetric exciting guided wave can detect the thinning section of the elbow, and the time domain energy value of the signal collected at the outer arch position of the receiving end displays a downward trend as the remaining thickness of the erosion area decreases. To address the difficulty in detecting the erosion degree of the elbow with high accuracy, this paper uses the linear frequency modulation (LFM) signal to excite a non-axisymmetric guided wave that propagates in the 90° elbow and collects signals through four PZT receivers. To predict the erosion degree, the corresponding relationship between the energy value of the four signals after fractional Fourier filtering and the degree of elbow erosion is established through the particle swarm optimization (PSO)-least squares support vector machine (LSSVM) algorithm. The results show that the method proposed has an average accuracy rate of 98.1864%, 94.7167%, 99.119%, and 99.9593% for predicting the erosion degree of four elbow samples, and 94.0039%. and 81.2976% for two new erosion degrees, which are higher than the nonlinear regression model, LSSVM algorithm, and BP neural network algorithm. This study has guiding significance for real-time monitoring of elbow erosion.

Active Ultrasonic Structural Health Monitoring Enabled by Piezoelectric Direct-Write Transducers and Edge Computing Process.

While the active ultrasonic method is an attractive structural health monitoring (SHM) technology, many practical issues such as weight of transducers and cables, energy consumption, reliability and cost of implementation are restraining its application. To overcome these challenges, an active ultrasonic SHM technology enabled by a direct-write transducer (DWT) array and edge computing process is proposed in this work. The operation feasibility of the monitoring function is demonstrated with Lamb wave excited and detected by a linear DWT array fabricated in situ from piezoelectric P(VDF-TrFE) polymer coating on an aluminum alloy plate with a simulated defect. The DWT array features lightweight, small profile, high conformability, and implementation scalability, whilst the edge-computing circuit dedicatedly designed for the active ultrasonic SHM is able to perform signal processing at the sensor nodes before wirelessly transmitting the data to a remote host device. The successful implementation of edge-computing processes is able to greatly decrease the amount of data to be transferred by 331 times and decrease the total energy consumption for the wireless module by 224 times. The results and analyses show that the combination of the piezoelectric DWT and edge-computing process provides a promising technical solution for realizing practical wireless active ultrasonic SHM system.

Crack Detection of Threaded Steel Rods Based on Ultrasonic Guided Waves.

Fatigue cracks are typical damage of threaded steel rods under dynamic loads. This paper presents a study on ultrasonic guided waves-based, fatigue-crack detection of threaded rods. A threaded rod with given sizes is theoretically simplified as a cylindrical rod. The propagation characteristics of ultrasonic guided waves in the cylindrical rod are investigated by semi-analytical finite element method and the longitudinal L(0, 1) modal ultrasonic guided waves in low frequency band is proposed for damage detection of the rod. Numerical simulation on the propagation of the proposed ultrasonic guided waves in the threaded rod without damage shows that the thread causes echoes of the ultrasonic guided waves. A numerical study on the propagation of the proposed ultrasonic guided waves in the threaded rod with a crack on the intersection of the smooth segment and the threaded segment shows that both linear indexes (Rf and ARS) and nonlinear indexes (ßre' and ß') are able to detect the crack. A constant-amplitude tensile fatigue experiment was conducted on a specimen of the threaded rod to generate fatigue cracks in the specimen. After every 20,000 loading cycles, the specimen was tested by the proposed ultrasonic guided waves and evaluated by the linear indexes and nonlinear indexes. Experimental results show that both the linear and nonlinear indexes of the ultrasonic guided waves are able to identify the crack before it enters the rapid growth stage and the nonlinear indexes detect the crack easier than the linear indexes.

Deep Learning Empowered Structural Health Monitoring and Damage Diagnostics for Structures with Weldment via Decoding Ultrasonic Guided Wave.

Welding is widely used in the connection of metallic structures, including welded joints in oil/gas metallic pipelines and other structures. The welding process is vulnerable to the inclusion of different types of welding defects, such as lack of penetration and undercut. These defects often initialize early-age cracking and induced corrosion. Moreover, welding-induced defects often accompany other types of mechanical damage, thereby leading to more challenges in damage detection. As such, identification of weldment defects and interaction with other mechanical damages at their early stage is crucial to ensure structural integrity and avoid potential premature failure. The current strategies of damage identification are achieved using ultrasonic guided wave approaches that rely on a change in physical parameters of propagating waves to discriminate as to whether there exist damaged states or not. However, the inherently complex nature of weldment, the complication of damages interactions, and large-scale/long span structural components integrated with structure uncertainties pose great challenges in data interpretation and making an informed decision. Artificial intelligence and machine learning have recently become emerging methods for data fusion, with great potential for structural signal processing through decoding ultrasonic guided waves. Therefore, this study aimed to employ the deep learning method, convolutional neural network (CNN), for better characterization of damage features in terms of welding defect type, severity, locations, and interaction with other damage types. The architecture of the CNN was set up to provide an effective classifier for data representation and data fusion. A total of 16 damage states were designed for training and calibrating the accuracy of the proposed method. The results revealed that the deep learning method enables effectively and automatically extracting features of ultrasonic guided waves and yielding high precise prediction for damage detection of structures with welding defects in complex situations. In addition, the effectiveness and robustness of the proposed methods for structure uncertainties using different embedding materials, and data under noise interference, was also validated and findings demonstrated that the proposed deep learning methods still exhibited a high accuracy at high noise levels.

Multi-Mode Ultrasonic Guided Waves Based Damage Detection in L-Bars with Asymmetric Cross-Section with Sum of Multiple Signals Method.

Bars are significant load-carrying components in engineering structures. In particular, L-bars are typical structural components commonly used in truss structures and have typical irregular asymmetric cross-sections. To ensure the safety of load-carrying bars, much research has been done for non-destructive testing (NDT). Ultrasonic guided waves have been widely applied in various NDT techniques for bars as a result of the long-range propagation, low attenuation, and high sensitivity to damages. Though good for inspection of ultrasonic guided waves in symmetric cross-section bar-like structures, the application in asymmetric ones lacks further research. Moreover, traditional damage detection in bars using ultrasonic guided waves usually depends on a single-mode at a lower frequency with lower sensitivity and accuracy. To make full use of all frequencies and modes, a multi-mode characteristic-based damage detection method is presented with the sum of multiple signals (SoM) strategy for L-bars with asymmetric cross-section. To control the desired mode in multi-mode ultrasonic guided waves, excitation optimization and weighted gathering are carried out by the analysis of the semi-analytical finite element (SAFE) method and the normal mode expansion (NME) method. An L-bar example with the asymmetric cross-section of 35 mm × 20 mm × 3 mm is used to specialize the proposed method, and some finite element (FE) models have been simulated to validate the mode control. In addition, one PZT is applied as a contrast in order to validate the multielement mode control. Then, more FE simulations experiments for damage detection have been performed to validate the damage detection method and verify the improvement in detection accuracy and damage sensitivity.

A New Probabilistic Ellipse Imaging Method Based on Adaptive Signal Truncation for Ultrasonic Guided Wave Defect Localization on Pressure Vessels.

Pressure vessels are prone to defects due to environmental conditions, which may cause serious safety hazards to industrial production. The probabilistic ellipse imaging method, based on ultrasonic guided wave, is a common method for locating defects on plate-like structures. In this paper, the research showed that the accuracy of the traditional probabilistic ellipse imaging method was severely affected by the truncation length of the signal. In order to improve the defect location accuracy of the probabilistic elliptic imaging algorithm, an adaptive signal truncation method based on signal difference analysis was proposed, and a novel probabilistic elliptic imaging method was developed. Firstly, the relationship model between the signal difference coefficient (SDC) and the distance coefficient was constructed. Through this model, the distance coefficient of each group signal can be calculated, so that the adaptive truncation length for each group of signals can be determined and the truncated signals used for defect imaging. Secondly, in order to improve the robustness of the new imaging method, the relationship between the defect location accuracy and SDC thresholds were investigated and the optimal threshold was determined. The experimental results showed that the probabilistic ellipse imaging algorithm, based on the new adaptive signal truncation method, can effectively locate a single defect on a pressure vessel.

Evaluation of the Transverse Crack Depth of Rail Bottoms Based on the Ultrasonic Guided Waves of Piezoelectric Sensor Arrays.

A method based on the high-frequency ultrasonic guided waves (UGWs) of a piezoelectric sensor array is proposed to monitor the depth of transverse cracks in rail bottoms. Selecting high-frequency UGWs with a center frequency of 350 kHz can enable the monitoring of cracks with a depth of 3.3 mm. The method of arranging piezoelectric sensor arrays on the upper surface and side of the rail bottom is simulated and analyzed, which allows the comprehensive monitoring of transverse cracks at different depths in the rail bottom. The multi-value domain features of the UGW signals are further extracted, and a back propagation neural network (BPNN) is used to establish the evaluation model of the transverse crack depth for the rail bottom. The optimal evaluation model of multi-path combination is reconstructed with the minimum value of the root mean square error (RMSE) as the evaluation standard. After testing and comparison, it was found that each metric of the reconstructed model is significantly better than each individual path; the RMSE is reduced to 0.3762; the coefficient of determination R2 reached 0.9932; the number of individual evaluation values with a relative error of less than 10% and 5% accounted for 100% and 87.50% of the total number of evaluations, respectively.

High-Sensitivity Ultrasonic Guided Wave Monitoring of Pipe Defects Using Adaptive Principal Component Analysis.

Ultrasonic guided wave monitoring is regularly used for monitoring the structural health of industrial pipes, but small defects are difficult to identify owing to the influence of the environment and pipe structure on the guided wave signal. In this paper, a high-sensitivity monitoring algorithm based on adaptive principal component analysis (APCA) for defects of pipes is proposed, which calculates the sensitivity index of the signals and optimizes the process of selecting principal components in principal component analysis (PCA). Furthermore, we established a comprehensive damage index (K) by extracting the subspace features of signals to display the existence of defects intuitively. The damage monitoring algorithm was tested by the dataset collected from several pipe types, and the experimental results show that the APCA method can monitor the hole defect of 0.075% cross section loss ratio (SLR) on the straight pipe, 0.15% SLR on the spiral pipe, and 0.18% SLR on the bent pipe, which is superior to conventional methods such as optimal baseline subtraction (OBS) and average Euclidean distance (AED). The results of the damage index curve obtained by the algorithm clearly showed the change trend of defects; moreover, the contribution rate of the K index roughly showed the location of the defects.

Review of Current Guided Wave Ultrasonic Testing (GWUT) Limitations and Future Directions.

Damage is an inevitable occurrence in metallic structures and when unchecked could result in a catastrophic breakdown of structural assets. Non-destructive evaluation (NDE) is adopted in industries for assessment and health inspection of structural assets. Prominent among the NDE techniques is guided wave ultrasonic testing (GWUT). This method is cost-effective and possesses an enormous capability for long-range inspection of corroded structures, detection of sundries of crack and other metallic damage structures at low frequency and energy attenuation. However, the parametric features of the GWUT are affected by structural and environmental operating conditions and result in masking damage signal. Most studies focused on identifying individual damage under varying conditions while combined damage phenomena can coexist in structure and hasten its deterioration. Hence, it is an impending task to study the effect of combined damage on a structure under varying conditions and correlate it with GWUT parametric features. In this respect, this work reviewed the literature on UGWs, damage inspection, severity, temperature influence on the guided wave and parametric characteristics of the inspecting wave. The review is limited to the piezoelectric transduction unit. It was keenly observed that no significant work had been done to correlate the parametric feature of GWUT with combined damage effect under varying conditions. It is therefore proposed to investigate this impending task.

Spectral Verification of the Mechanisms behind FBG-Based Ultrasonic Guided Wave Detection.

Ultrasonic guided wave (UGW) detection with fiber Bragg grating (FBG)-based sensors has received increasing attention in the last decades due to the ability to perform non-destructive inspection (NDI) of large plate-like surfaces with a network of lightweight and multiplexed sensors. For accurate UGW measurements, several studies concluded that the ratio between the wavelength of the UGW and the length of the FBG should be above 7. However, shorter FBGs suffer from a lower FBG reflectivity and less steep slopes in the reflection spectrum. In this work we experimentally verified the effect of a passing UGW on the Bragg peak of FBG sensors of different lengths. By performing edge-filtering interrogation throughout the FBG's reflection spectrum, we were able to reconstruct the FBG's spectral response to a UGW in function of time. Our experimental findings are partially in line with those in the literature considering the UGW wavelength to FBG length ratio and the corresponding Bragg peak changes. We experimentally show for the first time that for shorter FBG sensors, the strain modulation is translated mostly into Bragg peak shifting, while for longer FBG sensors, Bragg peak deformation takes over as main mechanism. Despite the different mechanism for the latter, the UGW can still be detected by edge-filtering on the steepest slope, and with a much higher sensitivity.

The Design and Verification of an Active SAMSR Ultrasonic Guided Wave Monitoring System with Ultra-Low Crosstalk.

Due to long propagation distance and high sensitivity to a variety of damages, ultrasonic guided wave technologies have been widely applied in the damage detection or health monitoring of pipe networks and large plate-like structures. However, there are two important problems to be solved when applying this technology; namely, the large scanning time required for monitoring large-scaled structures and the serious crosstalk between the actuation and receiving signals, especially when monitoring hot-spot regions. Therefore, this study mainly designed key parts, such as the matrix switcher and attenuation circuit. The single-actuation and multiple-simultaneous-reception (SAMSR) mechanism based on an analog switching matrix and a low noise charge amplifier circuit was designed and integrated with the SPI control bus to shorten the scanning time. Moreover, a two-stage attenuation circuit with an interlocking isolation structure is presented to effectively isolate the receiving signals from the actuation signals to obtain ultra-low crosstalk even under a high voltage actuation source. In this study, the designed matrix switcher and other components were integrated into the developed ultrasonic guided wave monitoring system. Several experiments were conducted on a stiffened composite structure to illustrate the effectivity of the developed SAMSR ultrasonic guided wave system by comparing the signals collected with those from a commercial ultrasonic guided wave system.

Ultrasonic Guided Wave Testing on Cross-Ply Composite Laminate: An Empirical Study.

Structural health monitoring comprises a set of techniques to detect defects appearing in structures. One of the most viable techniques is based on the guided ultrasonic wave test (UGWT), which consists of emitting waves throughout the structure, acquiring the emitted waves with various sensors, and processing the waves to detect changes in the structure. The UGWT of layered composite structures is challenging due to the anisotropic wave propagation characteristics of such structures and to the high signal attenuation that the waves experience. Hence, very low amplitude signals that are hard to distinguish from noise are typically recovered. This paper analyzes the propagation of guided waves along a cross-ply composite laminate following an empirical methodology. The research compares several implementations for UGWT with piezoelectric wafer active sensors. The reference for comparison is set on a basic mode, which considers the application of nominal voltage to a single sensor. The attenuation and spreading of the waves in several directions are compared when more energy is applied to the monitored structure. In addition, delayed multiple emission is also considered in multisensor tests. The goal of all the UGWT configurations is to transmit more energy to the structure such that the echoes of the emission are of greater amplitude and they ease the signal processing. The study is focused on the realization of viable monitoring systems for aeronautical composite made structures.

High-Resolution Crack Localization Approach Based on Diffraction Wave.

The delay-and-sum imaging algorithm is a promising crack localization approach for crack detection and monitoring of key structural regions. Most studies successfully offer a hole-like damage position. However, cracks are more common than hole-like damages in a structure. To solve this issue, this paper presents a crack localization approach, based on diffraction wave theory, which is capable of imaging crack endpoints. The guided wave propagated to the crack endpoints and transformed into a diffraction wave. A line sensor array was used to record the diffraction waveform. Then, dispersion compensation was applied to shorten the dispersive wave packets and separate the overlapping wave packets. Subsequently, half-wave compensation was executed to improve the localization accuracy. Finally, the effectiveness of this high-resolution crack localization method was validated by an experimental example.

Broadband Linear High-Power Amplifier Based on the Parallel Amplification Architecture for Electromagnetic Ultrasonic Guided Wave.

The linear power amplifier with high-output power in the broadband frequency is the critical component required by exciting the electromagnetic acoustic transducer (EMAT) to generate ultrasonic guided wave (UGW). The methods to realize the output of a high-power signal in the linear amplification mode and to expand the bandwidth at high-output power are seldom reported. To solve these problems, a power amplifier with differential structure is developed by using the parallel amplification architecture and the broadband feedback circuits. The proposed power amplifier uses a differential structure to suppress the even harmonic waves and remove the disruptions. Each branch of the differential structure consists of five linear power amplifier modules with output terminals connected in parallel to increase the output power. Also, the negative voltage feedback is used to extend the bandwidth of the power amplifier. The experimental results show that the -3 dB bandwidth of the amplifier is from 40 kHz to 2.5 MHz, and the transient output power is greater than 1 kW. The power amplifier can drive the EMATs to generate ultrasonic guided waves. Because of the high-output power and good linearity, the proposed power amplifier has excellent potential for EMAT UGW applications.