Hyunjo Jeong

Austenitic stainless steel is a widely used material in the industry, and the welding technique enables stainless steel components to have different shapes for different applications. Any flaws in the weld will degrade the performance of the austenitic component; thus, it is essential to ultrasonically and nondestructively test flaws in welds to ensure service safety. Recently, weld inspection has been performed using contact transducers, but missed detections or false positives for flaws in welds usually occur due to a poor coupling condition in the detection, a low signal-to-noise ratio, and instantaneous noises. In this study, a partial immersion focused (PIF) ultrasonic transducer is designed and used for austenitic weld inspection to address the above issues. The detailed design and manufacture of the PIF transducer are described, and the advantages of the transducer are shown by comparing the results detected using different kinds of transducers. In addition, in order to suppress false positives, a B-image method optimized using a time-dependent threshold is proposed. Experiments are performed to detect flaws in a welded specimen. All the artificial flaws are evaluated using the developed transducer and the proposed method, but minor flaws are mis-detected when planar transducers are used, verifying the method proposed in this paper.

Dual element transducers consisting of an outer ring transmitter and an inner disk receiver have been found to be an efficient alternative to single element transducers in SHG and pulse-echo beta measurements of solid specimens. The dual element structure provides improved SHG compared to single element transducers mainly because the phase difference other than pi between the two

The responsivity of an ultrasonic transducer is an important parameter in evaluating its effective frequency band, the electroacoustic conversion efficiency, and the measurement capability of the system. The determination of the responsivity of a traditional immersion or contact piezoelectric transducer has been well investigated. However, due to the high attenuation of waves propagating in air and the large acoustic impedance mismatch between the active piezoceramic material and the load medium, there are few reports of the calibration of an air-coupled piezoelectric transducer. In this work, we present a comparative method of measuring the responsivity of an air-coupled transducer: the air-coupled transducer is used to receive a broadband pulse signal to evaluate its frequency spectrum, and a toneburst signal with known vibration displacement is measured by the air-coupled transducer in order to calibrate the amplitude of the responsivity. The effects of transmitter responsivity, input pulse characteristics, attenuation, and diffraction are taken into account to improve the accuracy of the responsivity determination. In addition, the measurement of the amplitude of the responsivity by comparing the measured displacements avoids the complicated task of characterizing the effects of electrical equipment. The determined responsivity is checked by comparing the measured displacements using different methods at different frequencies in order to evaluate its frequency spectrum and by measuring the nonlinearity parameters of the material to evaluate its amplitude. The agreement between results obtained using different methods demonstrates that the calibrated responsivity of the air-coupled transducer is valid, and the proposed method is effective.

The through-transmission (TT) method is mainly used to measure the amplitude of the second harmonic from which the acoustic nonlinear parameter is determined for early damage detection of materials. The pulse echo (PE) method, however, has been excluded from nonlinear studies of solid materials because the stress-free boundary suppresses the generation of second harmonics. It is more demanding to develop the PE method for practical applications and this paper considers a novel phase shift technique of annular array transducers to improve second harmonic generation (SHG) at the stress-free boundary. The fundamental and second harmonic fields after phase-shifted radiation are calculated, and their received amplitudes are investigated. The phase difference between the two second harmonic components after reflection from the stress-free boundary is analyzed to explain the enhanced SHG. The PE method with optimal phase shift can generate an improved second harmonic amplitude as high as about 45% of the TT method. Four element array transducers are also found to be more efficient in improved SHG than two element transducers.

Nonlinear ultrasound is often employed to assess microdamage or nonlinear elastic properties of a material, and the nonlinear parameter is commonly used to quantify damage sate and material properties. Among the various factors that influence the measurement of nonlinear parameters, maintaining a constant contact pressure between the receiver and specimen is important for repeatability of the measurement. The use of an air-coupled transducer may be considered to replace the contact receiver. In this paper, a method of measuring the relative and absolute nonlinear parameters of materials is described using an air-coupled transducer as a receiver. The diffraction and attenuation corrections are newly derived from an acoustic model for a two-layer medium and the nonlinear parameter formula with all corrections is defined. Then, we show that the ratio of the relative nonlinear parameter of the target sample to the reference sample is equal to that of the absolute nonlinear parameter, and this equivalence is confirmed by measurements on three systems of aluminum samples. The proposed method allows the absolute measurement of the nonlinear parameter ratio or the nonlinear parameter without calibration of the air-coupled receiver and removes restrictions on the selection of reference samples.

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 (β)”, 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 β 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.