Ultrasonic Guided Waves for NDE OF WELDED STRUCTURES
an overview by
Krishnan Balasubramaniam Professor of Mechanical Engineering and Head of Centre for Nondestructive Evaluation Indian Institute of Technology, Madras Chennai 600 036 INDIA Tele: 044-445-8588 Email: balas@[Link] [Link]
Guided Wave Types
Based on Geometry
Surface Waves Plate Waves Cylindrical Waves Rod Waves
Based on Symmetry
Symmetric Anti-symmetric Axi-symmetric Non-axisymmetric
Based on Mode
Torsional Circumferential Longitudinal Shear Horizontal Shear Vertical Flexural
Plate Wave Basics
Anti - Symmetric Mode
Three basic wave mode types :
Shear Horizontal Shear Vertical
Symmetric anti-symmetric
Symmetric Mode
Longitudinal
Symmetric anti-symmetric
Guided Waves Characteristics
Dispersive (group .vs. phase) Contour Following Long Range Propagation Leaky Phenomena Multi-Mode Behavior Mode Specific Displacement and Stress Profiles. Null Zone
Plate Wave Simulation
T R
ANSYS FEM Model. Input impulse at 200 kHz. (2 cycles) at the top left corner. 4 cases displayed. Total Plate Length 12 inchs Total Plate Thickness 0.5 inchs. Defect Height 0.25
Plate Wave Simulation Results Defect Free Rectangular Defect
Corrosion
Crack
partial differential equation for particle motion in a continuous medium is given by
(+) u j,ij + u i,jj + i = i Since in a plate the domain is not infinite we require boundary conditions to solve these equations.
The solution of these two independent equations along with boundary condition, in this case 31 = 33 = 0 x = +- d/2
Rayleighs equations
tan(qh) 4k 2 qp 2 tan( ph) (k q 2 ) 2
tan( qh) ( k 2 q 2 ) 2 tan( ph) 4k 2 qp
for symmetric modes
for anti-symmetric modes
Lamb Waves in a steel plate
Mode Shapes
10 Phase velocity (km/sec)
s0 a1 s1 s2 a2
Top surface
Bottom surface
Propagation direction
a0
Frequency (MHz)
10
Dispersion of Pulses
1 2
Time (usecs)
Phase Velocity Dispersion Curves for Steel Plate
10 Phase velocity (km/s) 8 6 A1 S1
S2
A2
S0
4
A0 2
2 4 Frequency-Thickness (MHz-mm)
Group Velocity Dispersion Curves for Steel Plate
6
S0
Group velocity (km/s) S1
4
SH0 2 A0 0 0 SH1
A1
SH2 4
2 Frequency-Thickness (MHz-mm)
Attenuation Dispersion Curves for Steel Plate Immersed in Water
2000 1500
S1
A2
Att (dB-mm/m)
1000
A0 S2
4.0 6.0
500
S0
0 0.0 2.0
A1
Frequency-Thickness (MHz-mm)
Scholte
Types of Guided Wave Inspection
Short range (<<1m)
Medium range (up to ~5m) Long range (up to 100m)
Guided Wave Applications
Process Monitoring
Viscosity, Density, Level, Temperature
Material Characterization
Stiffness, Density, Visco-elastic, Ply-lay-up
Non-destructive Evaluation
Corrosion, Bond quality, Cracks, .
Data Communication
Dispersion Curves for pipes
Symmetric and Antisymmetric Mode Shapes
L(0,2)
F(1,3)
Guided Wave in Pipes
Corrosion Detection in Pipes
Alleyne et al Rev. of prog in QNDE Vol. 16, 1997
Test achieving 80m one direction range
0.8
Amp (mV)
0.6 0.4 0.2 0.0 0 20 40 60 80
Distance (m)
Corrosion at entrance to sleeved road crossing
1.0 -F4 -F3 -F2 -F1 +F1 +F2 +F3+F4
Amp (mV)
0.8 0.6 0.4 0.2 0.0 -30.0
-20.0
-10.0
0.0
10.0
Distance (m)
corrosion
Guided Wave Systems
Commercial Transducer System
Reflection coefficient for notch over 11% of pipe circumference as function of notch depth
Reflection coefficient from notch 50% of wall thickness deep as function of circumferential extent
Guided Waves in Pipes and Tubes
*Rose et al, Proc of WCNDT 1996
Energy Distributions for Selected Modes
Energy in the head
Energy in the web
Energy in the foot
Prototype System
System electronics User interface
Rail under test
clamping mechanism
transducer
Prototype System
Guided Ultrasonics (Rail) Ltd
Comparison predicted and experimental sensitivity 1
0.8
Experiment Finite eleme nt prediction
Reflection coefficient
0.6 0.4
0.2
0 0 10 20 30 40 50
Cross sectional area loss (%)
NDT by guided waves Inspection of Laser Welds of Tailored Blanks by SH-mode SS0
Probe
Ultrasonic w ave
Weld
Direction of Probe M otion
Probe-Soundfield
Weld Defects
Salzburger
NDT by guided waves Inspection of Laser Welds of Tailored Blanks
Probe
Blank is stationary - Probe is moved by a robot
Salzburger
NDT by guided waves Inspection of Laser Welds of Tailored Blanks by SH-mode SS0 Inspection result
Laser Weld Inspection
Scanning direction
Weld
Pos. 3 on X-ray film
End face
Ultrasonic B-image Microfocus X-ray
Salzburger
Guided Circumferential Waves
AEA Technology
NDT by guided waves In-motion Inspection of the running surface of Railway Wheels by Rayleigh waves
Amplitude RT RT RT
Crack Time of flight Tread in good condition
Ultrasonic A-Scan
Wheelbody
Ultrasonic Surface Wave Tread with defects Amplitude RT E E E RT E E
RT
Ultrasonic surface wave in the tread of the wheel
Time Timeof of flight flight
Probe
Probe
Inspection Principle
Salzburger
ENSURING THE OPERATIONAL RELIABILITY OF RAIL VEHICLES BY NONDESTRUCTIVE TESTING OF WHEEL SETS
Wheel set being tested
Wheel Testing by Guided Waves
Train moving over the probes
Probe 1
Probe 3
A-Scans from each of the four probes
Probe 2 Probe 4
Smart Pipe Concept
SMART PIPES that offer several advantages. This will use Acoustic Emission (AE) as the passive listening device and Guided Waves as the active device to interrogate the pipes for corrosion, cracking, and fatigue damage. The advantages would include reduction in routine inspection, the focus of inspection on regions with high probability of damage, the avoidance of removal of insulation during evaluation, ability to monitor the health of buried pipes, etc. It may be feasible to put-together a group of industries that can participate in defining the requirements. Some new technologies including (a) film based magetostrictive transduction, (b) flexi-sensor patch, (c) RF transmitter for AE data, etc. may be developed as a part of the effort.
Passive and Active Passive AE mode Passive Triggers Active mode Active mode Guided waves
Passive AE Sensor with RF
Band-Pass Filter
Amplifier
Threshold Algorithm RF-Trasmitter
Battery or solar panel operated Self maintenance features
Transducer Array Flexi-Patch
PZT crystal array or GMS film array
Mylar based PCB construction with Adhesive sticker like installation 50-200 kHz Freq 8-16 crystals/transducer
Guided Wave Smart Pipe
Non-dispersive Wave mode Low attenuation wave mode Low Leakage wave mode for embedded portions Controlling Parameters: Input Frequency and Signal BW
Summary
Guided Waves offer a new and effective
technique for evaluation of welded structures. Cost savings due to the long range nature of the technique Increased sensitivity due to multi-mode nature Ability to inspect in-accessible regions Ability to online monitor the welding process.
Inaccessible Pipeline inspection tools (PIGS)
MFL Inspection of gas pipelines
Defect
Differential Probe
Tube
Defect Characterization
MFL signal
Prediction with 1 resolution
Defect profile
Prediction with 2 resolutions
Defect Defect Geometry Geometry -- D: D: 50%, 50%, L: L: 3, 3, W: W: 3 3
