Development of an advanced multimode automatic ultrasonic texture measurement system for laboratory and production line application

We present work on the development of an ultrasonic texture measurement system for sheet metals using non-contact transducers, suitable for use both in the laboratory and on the production line. Variation of the velocity of the zero-order symmetric (S0) Lamb wave is used to determine the crystallographic texture of polycrystalline metal sheets ranging in thickness from 0.1 to 3 mm. This system features improvements on previous state-of-the-art ultrasonic technology in that it probes velocity over a continuous range of angles using only two electromagnetic acoustic transducers (EMATs). This is demonstrated to offer a significant improvement in accuracy and allows the detection and investigation of asymmetric anisotropies in the sheets. Another advantage of the system is its potential for combining several different measurements using a single pair of transducers. The capability is demonstrated for through-thickness shear wave measurements as well as the zero-order symmetric Lamb wave measurements which are the primary means of determining the texture. The change between generating Lamb and through-thickness bulk waves can be made entirely by changing the electrical circuit connected to the EMATs without modifying the transducer assembly in any way. Measurement of all of the above waves can provide information on the sheet thickness and other physical properties of the sheet in addition to texture. Certain texture parameters can be calculated from both Lamb and shear wave velocities, allowing self-calibration of the system.     

High accuracy non-contact ultrasonic thickness gauging of aluminium sheet using electromagnetic acoustic transducers.

Aluminium sheet thickness has been calculated from ultrasonic data obtained using a send-receive, radially polarised electromagnetic acoustic transducer (EMAT). Sheets in the thickness range between 0.1 and 0.5 mm have been measured using this non-contact approach at a stand-off of up to 1.5 mm. Normal incidence shear waves generated and detected in the sheet and the resultant waveforms have been processed using transit time measurements and Fourier analysis. Two broad band EMAT systems have been used to perform the measurements with centre frequencies of approximately 5 MHz and frequency content up to 10 and 20 MHz respectively. The most accurate measurements of thickness on thin sheets have been made using Fourier analysis and have yielded measurements accurate to within 0.2% (or 0.4 microm) for 280 microm thick aluminium sheets. Discrete shear wave echoes can be observed for sheets down to a thickness of 250 microm using the higher frequency EMAT system. However temporal measurements of these signals yield lower accuracy results when compared to the Fourier analysis method which is capable of sub-micron accuracy.     

Measurement of velocity variations along a wave path in the through-thickness direction in a plate

In this paper there is given a method to predict ultrasonic wave velocity variations along a wave path in the through-thickness direction in a plate from thickness resonance spectra. Thickness resonance spectra are numerically calculated and two simple rules used to predict the entire ultrasonic wave velocity variation are derived. In the calculation, the wave path is assumed to be straight along the thickness direction and the velocity variation is assumed to be either as a parabolic curve dependence or a linear dependence with respect to the distance from the surface and to be symmetric with respect to the plate center. To see if the numerical calculation method is reliable, thickness resonance frequencies of a sample with three-layers were measured by EMAT (electromagnetic acoustic transducer) with a good agreement between the measured and the calculated frequencies. This method can be applied to the ultrasonic measurement of material characteristics, internal stress or various other properties of plate materials.     

Reconstruction of the acoustic impedance profile in a plate using an inverse spectral procedure

An inverse spectral procedure was applied to reconstruct the acoustic impedance profile along the thickness direction of a plate using its thickness resonance frequencies, density and thickness. For a successful reconstruction, the material-property profile must be symmetric about the mid-plane of the plate. Several cases of numerical simulations, including plates with a few layers and with a high number of layers are described. The calculated resonance frequencies were used to reconstruct the acoustic impedance profile, a process that was successful for all cases. We assume that a plate with a high number of layers, each with a different but constant acoustic impedance, simulates a plate with a smoothly varying acoustic impedance profile. It can be concluded that such a plate, which generates small, virtually undetectable, internally reflected waves, can also be reconstructed. In the special case of a plate of unknown thickness and unknown but constant density, the method is still useful, because a relative variation of the material property can be reconstructed using only the resonance frequencies. An experiment using a resonance-mode electromagnetic acoustic transducer (resonance-mode EMAT) is also described. EMAT is a non-contact ultrasonic method that can measure thickness resonance frequencies, making it appropriate for this method. Some examples of applications are measurement of the temperature profile inside a rolled metal sheet, measurement of a clad metal plate, and monitoring of a metal casting.     

Shear Wave Field Radiated by an Electromagnetic Acoustic Transducer

The horizontally polarized ultrasonic shear wave field emitted by an electromagnetic acoustic transducer （EMAT） is studied by the surface force distribution on the EMAT approximately described as an inhomogeneous horizontal shear force. The shear wave directivity pattern is plotted by numerical calculations based on our strictly analytic solutions of the wave field we presented previously. An experimental system of EMAT generation and piezoelectric transducer reception is set up to check the predictions of the theoretical wave field by measuring the ultrasonic signals through aluminium block. The directivity pattern of the wave field obtained from the experimental results conforms the theoretical prediction, which lays a foundation for engineering applications of EMATs.     

Depth gauging of defects using low frequency wideband Rayleigh waves

In non-destructive testing for cracks it is not sufficient to simply detect the presence of a defect, but it is essential to have an accurate measure of the depth. Accurate calibration of the techniques used to gauge defect size is therefore necessary. Recent progress in the field of non-contact ultrasonic testing has led to the development of a practically viable system for generating and detecting wideband Rayleigh waves on electrically conducting or magnetic samples using electro-magnetic acoustic transducers (EMATs). This system has been used to gauge the depth and position of surface breaking defects, and has many applications including metal billet testing and detecting and sizing gauge corner cracking in rails. In this paper we report experiments calibrating the response of EMATs when a defect is present between the generator and receiver, using a calibration sample with slots machined perpendicular to the surface to simulate surface breaking cracks. The depth of the defect can be gauged in the time domain and frequency domain, with an accurate 'fingerprint' of the position given by an enhancement of the signal when the receiver is close to the defect. The best choice of EMAT design for different applications is discussed, as is the best position for the receive EMAT to avoid areas of interference between the Rayleigh wave and bulk waves diffracted from the crack tip.     

Resonance tracking and vibration stablilization for high power ultrasonic transducers

Resonant frequency shift and electrical impedance variation are common phenomena in the application of high power ultrasonic transducers, e.g. in focused ultrasound surgery and in cutting. They result in low power efficiency and unstable vibration amplitude. To solve this problem, a driving and measurement system has been developed to track the resonance of high power transducers and to stabilise their vibration velocity. This has the ability to monitor the operating and performance parameters of the ultrasonic transducers in real time. The configuration of the system, with its control algorithm implemented in LabVIEW (National Instruments, Newbury, UK), ensures flexibility to suit different transducers and load conditions. In addition, with different programs, it can be utilised as a high power impedance analyser or an instantaneous electrical power measurement system for frequencies in the MHz range. The effectiveness of this system has been demonstrated in detailed studies. With it, high transducer performance at high power can be achieved and monitored in real time.     

On-line measurement of texture,thickness and plastic strain ratio using laser-ultrasound resonance spectroscopy

Laser-ultrasound resonance spectroscopy, a non-contact ultrasonic technique, was used to determine reliably and rapidly the crystallographic texture, the average plastic strain ratio, and the thickness of sheet metal on the production line. As with laser-ultrasonics, a short laser pulse is used to generate a wide-band pulse of ultrasound and a laser interferometer is used for its detection. In this paper, a large number of echoes are collected and analyzed together using Fourier techniques to measure the natural resonance frequencies in the thickness of the sheet. One longitudinal and two shear resonance frequencies were measured together with their harmonics. From these frequencies, two crystallographic orientation distribution coefficients, W(400) and W(420), are obtained, as well as a highly accurate measurement of the sheet thickness that is corrected for changes in ultrasonic velocity caused by texture variations. Using these coefficients, the average and in-plane twofold and fourfold variations of the plastic strain ratio, respectively r delta(2)r, and delta(4)r, can be evaluated. These parameters are indications of the formability of metals sheets, which is of industrial interest. Measurements on 1 mm thick, low carbon steel sheets have shown the following measurement accuracies: r to within +/-0.08, delta(2)r, and delta(4)r to within +/-0.1, and thickness to better than +/-1 microm. On-line tests at LTV Steel Company showed that the sensitivity of the apparatus is sufficient to detect systematic variations in texture along the length of similar production coils and that the on-line repeatability for r was of order +/-0.02.     

一种磁场优化结构电磁超声传感器设计*

为了进一步增强电磁超声检测技术在管道厚度测量领域的检测能力,该文对电磁超声传感器(EMAT)的结构进行了优化。提出了多磁铁对称分布型EMAT,能实现更小的磁铁体积,产生更强的表面剩磁强度。采用在硅钢表面开槽的方式限制涡流形成的区域,解决了涡流对测量的影响。建立厚度测量实验系统,对比出单磁铁型与多磁铁对称分布型EMAT在不同提离距离上检测信号的变化规律。结果表明,多磁铁对称分布型结构可通过增强EMAT的偏置磁场达到信噪比更优的效果。采用耐高温探头外壳和钐钴磁铁,提高了EMAT探头在高温环境下的检测性能。     

Measurements of degree of sensitization (DoS) in aluminum alloys using EMAT ultrasound

Sensitization in 5XXX aluminum alloys is an insidious problem characterized by the gradual formation and growth of beta phase (Mg₂Al₃) at grain boundaries, which increases the susceptibility of alloys to intergranular corrosion (IGC) and intergranular stress-corrosion cracking (IGSCC). The degree of sensitization (DoS) is currently quantified by the ASTM G67 Nitric Acid Mass Loss Test, which is destructive and time consuming. A fast, reliable, and non-destructive method for rapid detection and the assessment of the condition of DoS in AA5XXX aluminum alloys in the field is highly desirable. In this paper, we describe a non-destructive method for measurements of DoS in aluminum alloys with an electromagnetic acoustic transducer (EMAT). AA5083 aluminum alloy samples were sensitized at 100 °C with processing times varying from 7 days to 30 days. The DoS of sensitized samples was first quantified with the ASTM 67 test in the laboratory. Both ultrasonic velocity and attenuation in sensitized specimens were then measured using EMAT and the results were correlated with the DoS data. We found that the longitudinal wave velocity was almost a constant, independent of the sensitization, which suggests that the longitudinal wave can be used to determine the sample thickness. The shear wave velocity and especially the shear wave attenuation are sensitive to DoS. Relationships between DoS and the shear velocity, as well as the shear attenuation have been established. Finally, we performed the data mining to evaluate and improve the accuracy in the measurements of DoS in aluminum alloys with EMAT.     

Theoretical examination of ultrasonic pole figures via comparison with the results analyzed by finite element polycrystal model

The ultrasonic wave velocities in a polycrystalline aggregate are sensitively influenced by texture development due to plastic deformation. According to Sayer's model, it is possible to construct ultrasonic pole figures via the crystallite orientation distribution function (CODF), which can be calculated by using ultrasonic wave velocities. In the previous papers, the theoretical modeling to simulate ultrasonic wave velocities propagating in solid materials under plastic deformation has been proposed by the authors and proved to be a good agreement with experimental results. Generally, wave velocities are dependent upon the propagating wave frequency; hence to evaluate texture development via ultrasonic pole figures it is necessary to examine an influence of frequency dependence on the ultrasonic wave velocities. In the present paper, the proposed theoretical modeling is applied to the texture characterization in polycrystalline aggregates of FCC metals under various plastic strain histories via ultrasonic pole figures, and also the frequency dependence is examined by using Granato-Lücke's dislocation strings model. Then the simulated ultrasonic pole figures are compared with the pole figures analyzed by the finite element polycrystal model (FEPM). The good qualitative agreement between both results suggests the sufficient accuracy of our proposed theoretical modeling.     

基于群速度失配的超声兰姆波二次谐波的时域测量方法

考虑到发射和接收换能器对超声兰姆波时域二次谐波信号所带来的不可避免的影响,提出一种基于基频与二倍频兰姆波群速度失配的超声兰姆波二次谐波的时域测量方法。当基频与二倍频超声兰姆波的相速度匹配而群速度失配时,在超声兰姆波传播过程中所发生的二次谐波信号,在时域上可与源于斜劈换能器的二次谐波信号相分离。采用仅源自于基频兰姆波的时域二次谐波的积分振幅,定量描述兰姆波二次谐波的发生效率。以铝板中传播的兰姆波为例,给出了时域二次谐波的具体测量过程。本文提出的测量方法放宽了超声兰姆波二次谐波的测量条件,且扣除了换能器对二次谐波信号所带来的影响,所测得的二次谐波信号完全来自于基频兰姆波时域信号的二次谐波发生效应。      

Hybrid laser/broadband EMAT ultrasonic system for characterizing cracks in metals

Detection and characterization of defects in metal parts in industrial and commercial settings has typically been carried out by nondestructive ultrasonic inspection systems. Correct measurement of crack size is critical for lifetime prediction inspections. Normally, measurements are made based on far-field ultrasonic diffraction models and time-of-flight reflection signals making accurate measurements for parts less than approximately 25 mm in thickness impossible. In this work a hybrid noncontacting laser generation/broadband electromagnetic acoustic transducer (EMAT) detection system is used to characterize ideal cracks in aluminum in which the far-field condition for ultrasonic diffraction cannot be met. Time domain signals show that diffracted energy is measured in the geometrical shadow zone of the crack. Fourier transform methods are used to show that the frequency content of the diffracted signals is different than those from the waves that do not interact with the crack. Crack size measurements are made by using the frequency content of the ultrasonic signal rather than time-of-flight information.     

Coupling mechanism of an EMAT

Electro-magnetic acoustic transducers (EMATs) generate ultrasonic waves in metals through an electromagnetic coupling mechanism. A concept for EMAT generation, using a coil alone without a permanent magnet, but with a pulse generator and a sample, is introduced. A simplified equivalent coil circuit is given, and has been validated by experimental measurements. Such an equivalent circuit is useful for excitation current calculations, which have often been neglected in previous publications in this area but have proved to be of great importance in considering the efficiency and frequency characteristics of ultrasonic generation. Due to the coil sample coupling, the equivalent coil inductance is dependent on the electrical conductivity and magnetic permeability of the metal sample, the lift-off, the coil orientation relative to the metal sample and the coil configuration. The use of a coil alone to generate ultrasound has limited applications as a suitable ultrasonic detector must also be used, but where appropriate this type of generation source provides a robust, non-contact and inexpensive means of ultrasonic generation without worrying the permanent magnet attracting ferromagnetic particles that can prevent from practical on-line application of EMATs.     

Bolt axial stress measurement based on a mode-converted ultrasound method using an electromagnetic acoustic transducer

A method is proposed to measure the stress on a tightened bolt using an electromagnetic acoustic transducer (EMAT). A shear wave is generated by the EMAT, and a longitudinal wave is obtained from the reflection of the shear wave due to the mode conversion. The ray paths of the longitudinal and the shear wave are analyzed, and the relationship between the bolt axial stress and the ratio of time of flight between two mode waves is then formulated. Based on the above outcomes, an EMAT is developed to measure the bolt axial stress without loosening the bolt, which is required in the conventional EMAT test method. The experimental results from the measurement of the bolt tension show that the shear and the mode-converted longitudinal waves can be received successfully, and the ratio of the times of flight of the shear and the mode-converted longitudinal waves is linearly proportional to the bolt axial tension. The non-contact characteristic of EMAT eliminates the effect of the couplant and also makes the measurement more convenient than the measurement performed using the piezoelectric transducer. This method provides a promising way to measure the stress on tightened bolts.     

W-Mo系复合材料的制备及其特性波阻抗

 采用放电等离子烧结技术，在相同的温度（1 473 K）及压力（30 MPa）下，制备出不同配比的致密的W-Mo系复合材料样品。采用高精度超声波脉冲回波重合方法，精确测量了超声波在样品中传播的横、纵波声速，并由此得到样品的特性波阻抗值。对样品的相组成分析及电子探针分析的结果表明，W-Mo系复合材料主要是以W、Mo机械混合的形式通过粘结相获得致密化的。因此，选用混合物模型对其特性波阻抗值进行了理论预测，与实测值的比较表明该模型能对W-Mo系复合材料的特性波阻抗作出比较准确的预测。     

Development of an ultrasonic inspection robot using an electromagnetic acoustic transducer for a Lamb wave and an SH-plate wave

For inspection of a storage tank and pipeline in service, the application of an automatic inspection system (nondestructive inspection robot) is desirable, because manual inspection is difficult to perfectly and exactly perform due to the enormous amount of inspection needed. However, an ultrasonic nondestructive inspection robot with a piezoelectric oscillator needs to touch only the material surface to be directly inspected using a coupling medium. That is, the material surface and the sensor must always be held by constant pressure in the vertical direction on the material side. Actually, it is difficult to overcome these problems; thus an ultrasonic inspection robot could not be widely applied. We then tried to develop an ultrasonic inspection robot with an electromagnetic acoustic transducer (EMAT) which did not require a coupling medium to inspect the circumferential pipe parts. We developed a special EMAT that could transmit and receive alternately a Lamb wave with high sensitivity and a SH-plate wave without influence by the welded part. The method by which the inspection robot turned around the direction of the steel pipe surroundings was executed by observing the tape pasted in the direction of the steel pipe surroundings with an installed CCD camera. In this report, the basic mechanism of this inspection robot and an examination of results are described.     

铝在校正高压下物质弹性波速测量上的应用

 自从在紧装式六面顶高压装置上建立了高温超高压下弹性波速的测量方法之后，已经获得了大量的有关岩石矿物的波速数据，利用这些波速数据解决了许多地质问题。然而，其高压弹性波速数据的精度没有解决，一直无法校正上、下顶砧的真正走时。根据弹性理论和标准物质铝的有关弹性参数，计算出铝的波速与压力的关系，然后，根据铝的波速与压力的关系推导出上、下顶砧的实际走时，校正后测量的较低压力下铁的波速与前人的资料吻合很好，并且铁的波速与压力也具有较好的非线性关系。因而，今后可以根据标准物质铝和铁来校正上、下顶砧的走时，从而获得物质在高压下更加精确的波速数据。     

A model and experimental study of fiber orientation effects on shear wave propagation through composite laminates

The strong elastic anisotropy of the discrete unidirectional plies in a composite laminate interacts sensitively with the polarization direction of a shear ultrasonic wave propagating in the thickness direction. The transmitted shear wave can therefore be used to detect errors in the ply orientation and stacking sequence of a laminate. The sensitivity is particularly high when the polarization directions of the shear wave transmitter and receiver are orthogonal to each other. To understand the interaction between normal-incident shear waves and ply orientations in a laminate, a complete analytical model was developed using local and global transfer matrices. The model predicted the transmitted signal amplitude as a function of polarization angle of the transmitter and time (or frequency) for a given laminate and input signal. To alleviate the experimental problems associated with shear wave coupling, electromagnetic acoustic transducers (EMATs) and metal delay lines were used in the angular scan of the transmitted signal. The EMAT system had the added advantage of being applicable to uncured composite laminates. Experiments were performed on both cured and uncured laminates with common layups for model verification. The sensitivity of the measured shear wave signals to fiber misorientation and stacking sequence errors was also demonstrated.     

Ultrasonic monitoring of malolactic fermentation in red wines

The progress of malolactic fermentation in red wines has been monitored by using ultrasonic techniques. The evolution of ultrasonic velocity of a tone burst 1 MHz longitudinal wave was measured, analyzed and compared to those parameters of oenological interest obtained simultaneously by analytical methods. Semi-industrial tanks were used during measurements pretending to be in real industrial conditions. Results showed that the ultrasonic velocity mainly changes as a result of the conversion by lactic acid bacteria of malic acid into lactic acid and CO₂. Overall, the present study has demonstrated the potential of the ultrasonic technique in monitoring the malolactic fermentation process.