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AEEM-7028
Ultrasonic NDE
Part 1
Introduction to Ultrasonics
What is ultrasonics?
Ultrasonics is a branch of acoustics dealing with the generation and use of (generally) inaudible acoustic waves.
low-intensity applications:
to convey information through a system
to obtain information from a system
1 3
avg 10 10 WP − −≈ −
2 4
peak 10 10 WP ≈ −
5 1010 10 Hzf ≈ −
high-intensity applications:
to permanently alter a system
2 4
avg 10 10 WP ≈ −
4 510 10 Hzf ≈ −
What is Nondestructive NDE?
Methods of NDE
Visual
Liquid Penetrant
Magnetic Particle
Eddy Current
Ultrasonic
X-ray
Microwave
Acoustic Emission
Thermography
Laser Interferometry
Replication
Flux Leakage
Acoustic Microscopy
Magnetic Measurements
Tap Testing
Terminology:
ultrasonic nondestructive inspection (NDI)
ultrasonic nondestructive testing (NDT)
ultrasonic nondestructive evaluation (NDE)
Main Fields of Ultrasonic NDE:
material production processes
material integrity following transport, storage and fabrication
the amount and rate of degradation during service
Ultrasonics versus Ultrasonic NDE
Ultrasonics (high-frequency wave
propagation in idealized elastic media)
Wave-Material Interaction (special physical phenomena due to interaction with imperfections)
Ultrasonic NDE
defect-free reflection, diffraction attenuation, velocity change
scattering, nonlinearity
defects cracks, voids
misbonds, delaminations isotropic anisotropy (orientation)
birefringence (polarization) quasi-modes (three waves) phase and group directions
residual stress effect
anisotropy texture
columnar grains prior-austenite grains
composites homogeneous incoherent scattering noise
attenuation dispersion (weak)
inhomogeneneity polycrystalline
two-phase porous
composite linear harmonic generation
acousto-elasticity crack-closure
nonlinearity intrinsic (plastics) damage (fatigue)
attenuation-free absorption viscosity, relaxation
heat conduction, scattering
elastic inhomogeneity geometrical irregularity
attenuation air, water, viscous couplants
polymers coarse grains
porosity
dispersion-free relaxation resonance
wave and group velocity pulse distortion
dispersion intrinsic (polymers)
geometrical (wave guides)
temperature-independent velocity change thermal expansion
temperature-dependence nonlinearity
residual stress (composites) phase transformation (metals) moisture content (polymers)
ideal boundaries flat, smooth,
rigidly bonded interface
mode conversion refraction, diffraction
scattering
imperfect boundaries curved, rough
slip, kissing, partial, interphase canonical wave types
plane wave spherical waves
harmonic
beam spread diffraction loss
edge waves spectral distortion
complex wave types apodization (amplitude)
focusing (phase) impulse, tone-burst
Simple Harmonic Wave
x
λ
t = t1t2
t3
cu
u0
-u0
0( , ) cos[ ( ) ]xu x t u tc
= ω − + ϕ
u displacement 0u denotes the amplitude 2 fω = π is the angular frequency f is the cyclic frequency ϕ is the phase angle at 0x t= = c denotes the propagation (phase) velocity
( )
0( , ) i k x tu x t U e± − ω= 0U is a complex amplitude 2 /k = π λ is the wave number λ is the wavelength
0 cos( )xu u e k x t−α= − ω − ϕ α is an attenuation coefficient
Standing Wave
0 0cos( ) cos( )u u k x t u k x t= +ω + −ω 02 cos( ) cos( )u k x t= ω
Successive instants of standing wave vibration in a specimen.
x
λ
t = t1t2
t3
unode
antinode
u0
-2u0
2
A node is a point, line, or surface of a vibrating body that is free from vibratory motion.
Arbitrary Pulse and Harmonic Wave Packet
u
x
c
u
x
c
f ( x - c t )cos [ k ( x - c t ) ]
f ( x - c t ) f ( x - c [ t + dt ] )
Pulse of arbitrary shape
( )u f x ct= − Oscillatory wave packet
( )cos[ ( )]u f x ct k x ct= − −
Fundamental Wave Modes Bulk Waves: Longitudinal Wave:
wavedirection
Shear Wave:
wavedirection
Guided Waves:
e.g., Surface Wave:
wavedirection
rod waves, Lamb waves in plates, etc.
Static Uniaxial Load
L
A
PP
L + u
1. Deformation
planes originally normal to the axis remain normal, but their separation changes 2. Strain
uL
ε =
3. Stress
Eσ = ε , ε = − νε 4. Load
AP dA A= σ = σ∫
5. Displacement
P LuE A
=
Fundamental Longitudinal Mode
( )u u x=
dxx
u
dx
σ ∂σσ + dx∂x
Equation of motion:
2
2( ) udx A A Adxx t
∂σ ∂σ + −σ = ρ∂ ∂
2
2u
x t∂σ ∂= ρ∂ ∂
A cross-sectional area
ρ mass density
Constitutive equation:
Eσ = ε
ε axial strain
E Young's modulus
Displacement-strain relationship:
ux
∂ε =
∂
Wave equation:
2 2
2 2u uE
x t∂ ∂
= ρ∂ ∂
2 2
2 2 2rod
1u ux c t∂ ∂
=∂ ∂
longitudinal wave velocity in a thin rod
rodEc =ρ
rodsin[ ( )]u A k x c t= −
rod( )u f x c t= −
Solution of the General Wave Equation
2 2
2 2 21u u
x c t∂ ∂
=∂ ∂
where c is the wave velocity:
stiffnessvelocitydensity
=
Propagating harmonic wave represents a solution of the wave equation:
0( , ) cos[ ( ) ]xu x t u tc
= ω − + ϕ
Arbitrary wave pulse of the general form ( , ) ( )xu x t f tc
= − also satisfies the wave
equation:
2
2 ( , ) ''( )xu x t f tct
∂= −
∂
2
2 21( , ) ''( )xu x t f t
cx c∂
= −∂
Static Torsional Load
circular cross section (no warping):
LJ
θ
d
TTγ
1. Deformation planes originally normal to the axis remain normal, their separation remains the same, but
they rotate in their in their own plane, i.e., around to the axis 2. Strain
rLθ
γ =
3. Stress Gτ = γ , where 2(1 )E G= +ν
4. Load 2
A A
G G JT r dA r dAL Lθ θ
= τ = =∫ ∫
2
AJ r dA= ∫∫ polar moment
5. Displacement
T LG J
θ =
Static Torsional Load (cont.)
arbitrary cross section (warping)
TT
t
T LG J
θ =
tJ twisting moment
Saint-Venant approximation
4 4
2 404tA AJ
JJ≈ ≈
π
Fundamental Torsional Mode
fundamental mode: ( )xθ = θ
dx
θT + dTT
γ + dθ θ
Equation of motion: 2
2dT J dxt
∂ θ= ρ
∂
tT G Jx∂θ
=∂
2 2
2 2tG J Jx t∂ θ ∂ θ
= ρ∂ ∂
2 2
2 2 21
tx c t∂ θ ∂ θ
=∂ ∂
t tt s
G J Jc cJ J
= =ρ
Fundamental String Mode
no bending moment
Ax
vy,
x
T + dTζT
dx
dθvy,
Curvature:
dx d= ζ θ
1''ddxθ= =
ζv
Equation of motion: 2
2T d Adxt
∂θ = ρ
∂v
2 2
2 2T Ax t∂ ∂
= ρ∂ ∂v v
2 2
2 2 2string
1x c t∂ ∂
=∂ ∂v v
stringTc σ
=ρ
TTA
σ = tension stress
Simple Bending Deformation
Ix
vy,
xM M
ζvy,
1. Deformation
planes originally normal to the axis remain normal, on the average their separation remains the same, but they rotate around the axis of moment
2. Strain
''y yε = − = −ζ
v
3. Stress
Eσ = ε 4. Load
2'' ''A A
M y dA E y dA E I= − σ = =∫ ∫v v
' '''V M E I= − = − v
' ''''q V E I= − = v
5. Displacement
2''dx= ∫∫v v
Fundamental Flexural Mode in a Thin Rod
4
4I E qx
∂=
∂v
I moment of inertia
v transverse displacement
q distributed load intensity for a unit length
Inertia forces decelerating the beam
2
2q At
∂= − ρ
∂v
A cross-sectional area
For harmonic vibrations
sin[ ]k x t= − ωov v
4 4 4x k∂ ∂ =/
2 2 2t∂ ∂ = −ω/
4 2I E k A= ρ ω
Dispersion of Flexural Waves propagating modes:
24f
I Eck Aω ω
= = ±ρ
non-propagating modes:
24f
I Ec ik Aω ω
= = ±ρ
For a rectangular bar of height h
2 24 rod0.5373
12fE hc c hω
= = ωρ
rodc E= ρ/ longitudinal wave velocity in the thin rod
For a thin plate of thickness h
E → 2(1 )E − ν/
2 24
212(1 )fE hc ω
=− ν ρ
For a cylindrical rod of diameter d
2 16I A d=/ /
rod0.5fc c d= ω
Which Guided Wave Mode To Use?
• generation/detection
• loading/damping/leaking
• dispersion
• vibration profile/distribution
Wave Types in Solids and Fluids Extended (bulk) fluid medium:
longitudinal (compressional, dilatational, pressure) Extended (bulk) solid medium:
longitudinal (dilatational)
shear (transverse, equivoluminal) Solid half-space:
surface (Rayleigh) wave Solid plate:
plate (Lamb) waves
Rods, strings, etc.
stiffnessvelocitydensity
=
Dilatational Modes thin rod aligned with the x-direction ( 0y zσ = σ = )
x xEσ = ε
rodEc =ρ
thin plate parallel to the x-y plane ( 0y zε = σ = )
21x xE
σ = ε− ν
ν Poisson's ratio
rodplate rod2 2
1.05 (for 0.3)(1 ) 1
cEc c= = ≈ ν =− ν ρ − ν
infinite medium ( 0y zε = ε = )
2(1 )
(1 )(1 2 )211
x x xE E − ν
σ = ε = ε+ ν − νν−
− ν
rod rod(1 ) (1 ) 1.16
(1 )(1 2 ) (1 )(1 2 )dEc c c− ν − ν
= = ≈+ ν − ν ρ + ν − ν
Acoustic Waves in a Gas
p RT= ρ gas equation
T absolute temperature
R gas constant For an adiabatic process
p K γ= ρ
bulk modulus
B p K γ= ρ∂ ∂ρ = γ ρ/
d Bc = ρ/
od
pRTc
γ= = γ
ρ
po static (ambient) pressure
p vc cγ = / specific-heat ratio
Transverse (Shear) Waves longitudinal transverse (dilatational, compressional) (shear)
x
σx
σy
σx-
σy-
y
ux
-τ
x
τyx
yx
τxy−τxy
uy
xy xyτ = μγ (µ = G)
y
xyux
∂γ =
∂
2 2
2 2 21y y
s
u u
x tc
∂ ∂=
∂ ∂
sc μ=
ρ
2 21 2
d
s
cc
− ν=
− ν, 2
1plate
s
cc
=−ν
, 2(1 )rod
s
cc
= +ν
Acoustic Impedance The relationship between stress σ, displacement u, and particle velocity v for a propagating wave is of interest. As an example, let us consider a dilatational wave propagating in an infinite elastic medium:
( )( , ) i k x txu x t Ae − ω=
( )( , ) x i k x tx
ux t i Aet
− ω∂= = − ω
∂v
( )x i kx tx xx xx
uC C Ai k ex
− ω∂= =σ
∂
The ratio of the pressure (or negative stress) to the particle velocity is called the acoustic impedance. For a dilatational wave propagating in the positive direction,
2 ( )
( )
i kx tx d
d di k x tx
c Ai k eZ c
i Ae
− ω
− ωρσ= − = = ρωv
d dZ c= ρ
The product of density and wave velocity occurs repeatedly in acoustics and ultrasonics and is called the characteristic acoustic impedance (for a plane wave). It is the impedance that acoustically differentiates materials, in addition to the moduli and density. Similarly, for shear waves
s sZ c= ρ
Densities, Acoustic Velocities and Acoustic Impedances of Some Materials
Material Density, [103 kg/m3]
ρ
Acoustic velocities [103 m/s]
long. dc shear sc
Acoustic impedance
[106 kg/m2s] dZ
Metals
Aluminum 2.7 6.32 3.08 17 Iron (steel) 7.85 5.90 3.23 46.5 Copper 8.9 4.7 2.26 42 Brass 8.55 3.83 2.05 33 Nickel 8.9 5.63 2.96 50 Tungsten 19.3 5.46 2.62 105 Nonmetals
Araldit Resin 1.25 2.6 1.1 3.3 Aluminum oxide 3.8 10 38 Glass, crown 2.5 5.66 3.42 14 Perspex (Plexiglas) 1.18 2.73 1.43 3.2 Polystyrene 1.05 2.67 2.8 Fused Quartz 2.2 5.93 3.75 13 Rubber, vulcanized 1.4 2.3 3.2 Teflon 2.2 1.35 3.0 Liquids
Glycerine 1.26 1.92 2.4 Water (at 20oC) 1.0 1.483 1.5
Wave Dispersion
Dispersion means that the propagation velocity is frequency-dependent. Since the phase relation between the spectral components of a broadband signal varies with distance, the
pulse-shape gets distorted and generally widens as the propagation length increases.
input pulse
ω∂c > 0∂
ω∂c = 0∂
ω∂c < 0∂
Group Velocity
dispersive wave propagation of a relatively narrow band “tone-bursts”
phase velocity versus group velocity
phasevelocity
groupvelocity
Beating Between Two Harmonic Signals
1 1cos( )u t= ω
2 2cos( )u t= ω
1 2 1 2
1 2 1 2cos( ) cos( ) 2cos( ) cos( )2 2
u u t t t tω +ω ω −ω+ = ω + ω =
( , ) cos( ) cos[( ) ( ) ]
2cos( )cos( )2 2
u x t kx t k k x tkk x t x t
= − ω + + δ − ω + δωδ δω
≈ − ω −
The first high-frequency term is called carrier wave and the second low-frequency term is
the modulation envelope. This shows that the propagation velocity of the carrier is the phase velocity and the propagation velocity of the modulation envelope is the group
velocity:
Phase Velocity versus Group Velocity Carrier or phase velocity
2
2
pc k kk
δωω + ω= ≈
δ+
Envelope or group velocity
gck k
δω ∂ω= →
δ ∂
Characteristic equation
( , ) 0pF c k = or ( )p pc c k=
pk cω =
p
g pc
c c kk
∂= +
∂
Dispersion equation
( )p pc c= ω
1
pg
p
p
cc c
c
=∂ω
−∂ω
Spectral Representation In the case of dispersive wave propagation,
( ) becomes ( )( )
x xf t f tc c
− −ω
Let us assume that f(t) is known at x=0. Fourier transform:
{ ( )} ( ) ( ) exp( )f t F dt f t i t∞
−∞= ω = − ω∫F
Inverse Fourier transform:
1{ ( )} ( ) ( ) exp( )2
F f t d F i t∞
−∞ω = = ω ω ω∫
πF -1
Shift theorem:
{ ( )} ( ) exp( )p pf t t F i t− = ω − ωF
Dispersive wave propagation:
( , ) ( ,0) exp[ ] ( ,0) exp[ ( )]( )xF x F i F i xk
cω = ω − ω = ω − ω
ω
Material versus Geometrical Dispersion
Frequency [MHz]
Vel
ocity
[km
/s]
2.6
2.7
2.8
0 2 4 6 8 10
polyethylene
phase
group
lowest-order symmetric Lamb mode in a 1-mm-thick aluminum plate
Frequency [MHz]
Vel
ocity
[km
/s]
0
2
4
6
0 2 4 6
phase
group