Vladimir Bardakov

The paper considers the neural network application to detect microstructure defects in dissimilar welded joints using the acoustic emission (AE) method. The peculiarity of the proposed approach is that defect detection is carried out taking into account a priori information about the properties of the AE source and the acoustic waveguide parameters of the testing structure. Industrial process pipelines with dissimilar welded joints were studied as the testing object, and diffusion interlayers formed in fusion zones of welded joints were considered microstructure defects. The simulation of AE signals was carried out using a hybrid method: the signal waveform was determined based on a finite element model, while the amplitudes of AE hits were determined based on a physical experiment on mechanical testing of dissimilar welded joints. Measurement data from industrial process pipelines were used as noise realizations. As a result, a data sample was formed that considered the parameters of the AE source and the parameters of the acoustic waveguide with realistic noise parameters and a signal-to-noise ratio. The proposed method allows for a more accurate determination of the waveform, spectrum, and amplitude parameters of the AE signal. Greater certainty in the useful signal parameters allows for achieving a more accurate and reliable classification result. When using a backpropagation neural network, a percentage of correct classification of more than 90% was obtained for a data set in which the signal-to-noise ratio was less than (−5 dB) in 90% of cases.

Estimation of probability of defect detection (POD) is one of the most important problems in acoustic emission (AE) testing. It is caused by the influence of the material microstructure parameters on the diagnostic data, variability of noises, the ambiguous assessment of the materials emissivity, and other factors, which hamper modeling the AE data, as well as the a priori determination of the diagnostic parameters necessary for calculating POD. In this study, we propose an empirical approach based on the generalization of the experimental AE data acquired under mechanical testing of samples to a priori estimation of the AE signals emitted by the defect. We have studied the samples of common industrial steels 09G2S (similar to steel ANSI A 516-55) and 45 (similar to steel 1045) with fatigue cracks grown in laboratory conditions during cyclic testing. Empirical generalization of data using probabilistic models enables estimating the conditional probability of record emissivity and amplitudes of AE signals. This approach allows to eliminate the existing methodological gap and to build a comprehensive method for assessing the probability of fatigue cracks detection by the AE testing.

For the effective detection of acoustic emission (AE) impulses against a noisy background, the correct assessment of AE parameters, and an increase in defect location accuracy during data processing are needed. For these goals, it is necessary to consider the waveform of the AE impulse. The results of numerous studies have shown that the waveforms of AE impulses mainly depend on the properties of the waveguide, the path along which the signal propagates from the source to the sensor. In this paper, the analytical method for modeling of AE signals is considered. This model allows one to obtain model signals that have the same spectrum and waveform as real signals. Based on the obtained results, the attenuation parameters of the AE waves for various characteristics of the waveguide are obtained and the probability of defect detection at various distances between the AE source and sensor utilized for evaluation.