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Advanced Ultrasonic Methods for Material and Structure Inspection This page intentionally left blank Advanced Ultrasonic Methods for Material and Structure Inspection Edited by Tribikram Kundu Series Editor Dominique Placko First published in Great Britain and the United States in 2007 by ISTE Ltd Apart from any fair dealing for the purposes of research or private study, or criticism or review, as permitted under the Copyright, Designs and Patents Act 1988, this publication may only be reproduced, stored or transmitted, in any form or by any means, with the prior permission in writing of the publishers, or in the case of reprographic reproduction in accordance with the terms and licenses issued by the CLA. Enquiries concerning reproduction outside these terms should be sent to the publishers at the undermentioned address: ISTE Ltd 6 Fitzroy Square London W1T 5DX UK ISTE USA 4308 Patrice Road Newport Beach, CA 92663 USA www.iste.co.uk © ISTE Ltd, 2007 The rights of Tribikram Kundu to be identified as the author of this work have been asserted by him in accordance with the Copyright, Designs and Patents Act 1988. Library of Congress Cataloging-in-Publication Data Advanced ultrasonic methods for material and structure inspection/edited by Tribikram Kundu. p. cm. Includes bibliographical references and index. ISBN-13: 978-1-905209-69-9 ISBN-10: 1-905209-69-X 1. Ultrasonic testing. I. Kundu, T. (Tribikram) TA417.4.A38 2006 620.1'1274--dc22 2006032329 British Library Cataloguing-in-Publication Data A CIP record for this book is available from the British Library ISBN 10: 1-905209-69-X ISBN 13: 978-1-905209-69-9 Printed and bound in Great Britain by Antony Rowe Ltd, Chippenham, Wiltshire. To my wife, Nupur, our daughters, Ina and Auni and our parents, Makhan Lal Kundu, Sandhya Rani Kundu, Jyotirmoy Naha and Rubi Naha This page intentionally left blank Table of Contents Preface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xiii Chapter 1. An Introduction to Failure Mechanisms and Ultrasonic Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Kumar V. JATA, Tribikram KUNDU and Triplicane A. PARTHASARATHY 1 1.1. Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2. Issues in connecting failure mechanism, NDE and SHM . 1.3. Physics of failure of metals . . . . . . . . . . . . . . . . . . 1.3.1. High level classification . . . . . . . . . . . . . . . . . . 1.3.1.1. Deformation . . . . . . . . . . . . . . . . . . . . . . . 1.3.1.2. Fracture. . . . . . . . . . . . . . . . . . . . . . . . . . 1.3.1.3. Dynamic fatigue . . . . . . . . . . . . . . . . . . . . 1.3.1.4. Material loss . . . . . . . . . . . . . . . . . . . . . . . 1.3.2. Second level classification . . . . . . . . . . . . . . . . 1.3.2.1. Deformation due to yield . . . . . . . . . . . . . . . 1.3.2.2. Creep deformation and rupture . . . . . . . . . . . . 1.3.2.3. Static fracture . . . . . . . . . . . . . . . . . . . . . . 1.3.2.4. Fatigue . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3.2.5. Corrosion. . . . . . . . . . . . . . . . . . . . . . . . . 1.3.2.6. Oxidation. . . . . . . . . . . . . . . . . . . . . . . . . 1.4. Physics of failure of ceramic matrix composites . . . . . . 1.4.1. Fracture. . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4.1.1. Mechanical loads and fatigue . . . . . . . . . . . . . 1.4.1.2. Thermal gradients. . . . . . . . . . . . . . . . . . . . 1.4.1.3. Microstructural degradation. . . . . . . . . . . . . . 1.4.2. Material loss . . . . . . . . . . . . . . . . . . . . . . . . . 1.5. Physics of failure and NDE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 2 4 4 5 5 6 7 7 7 9 12 13 18 20 21 23 23 24 25 25 26 viii Advanced Ultrasonic Methods for Material and Structure Inspection 1.6. Elastic waves for NDE and SHM . . . . . . . . . . . . . . . . . . . . 1.6.1. Ultrasonic waves used for SHM . . . . . . . . . . . . . . . . . . 1.6.1.1. Bulk waves: longitudinal and shear waves . . . . . . . . . . 1.6.1.2. Guided waves: Rayleigh and Lamb waves, bar, plate and cylindrical guided waves . . . . . . . . . . . . . . . . . . . . . . . . . 1.6.2. Active and passive ultrasonic inspection techniques . . . . . . 1.6.3. Transmitter-receiver arrangements for ultrasonic inspection . 1.6.4. Different types of ultrasonic scanning. . . . . . . . . . . . . . . 1.6.5. Guided wave inspection technique. . . . . . . . . . . . . . . . . 1.6.5.1. One transmitter and one receiver arrangement. . . . . . . . 1.6.5.2. One transmitter and multiple receivers arrangement . . . . 1.6.5.3. Multiple transmitters and multiple receivers arrangement . 1.6.6. Advanced techniques in ultrasonic NDE/SHM . . . . . . . . . 1.6.6.1. Lazer ultrasonics . . . . . . . . . . . . . . . . . . . . . . . . . 1.6.6.2. Measuring material non-linearity . . . . . . . . . . . . . . . 1.7. Conclusion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.8. Bibliography . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 26 27 . . . . . . . . . . . . . . . . . . . . . . . . . . 28 30 30 31 32 32 35 36 36 36 37 38 38 Chapter 2. Health Monitoring of Composite Structures Using Ultrasonic Guided Waves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Sauvik BANERJEE, Fabrizio RICCI, Frank SHIH and Ajit MAL 43 2.1. Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.2. Guided (Lamb) wave propagation in plates . . . . . . . . . . . . . . . 2.2.1. Lamb waves in thin plates. . . . . . . . . . . . . . . . . . . . . . . 2.2.2. Lamb waves in thick plates . . . . . . . . . . . . . . . . . . . . . . 2.3. Passive ultrasonic monitoring and characterization of low velocity impact damage in composite plates . . . . . . . . . . . . . . . . . . . . . . 2.3.1. Experimental set-up . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3.2. Impact-acoustic emission test on a cross-ply composite plate. . 2.3.3. Impact test on a stringer stiffened composite panel . . . . . . . . 2.4. Autonomous active damage monitoring in composite plates . . . . . 2.4.1. The damage index . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.4.2. Applications of the damage index approach . . . . . . . . . . . . 2.5. Conclusion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.6. Bibliography . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 46 51 55 . . . . . . . . . . . . . . . . . . 60 60 64 71 75 76 77 85 86 Chapter 3. Ultrasonic Measurement of Micro-acoustic Properties of the Biological Soft Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Yoshifumi SAIJO 89 3.1. Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.2. Materials and methods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89 91 Table of Contents 3.2.1. Acoustic microscopy between 100 and 200 MHz . 3.2.2. Sound speed acoustic microscopy . . . . . . . . . . 3.2.3. Acoustic microscopy at 1.1 GHz . . . . . . . . . . . 3.3. Results. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.3.1. Gastric cancer . . . . . . . . . . . . . . . . . . . . . . 3.3.2. Renal cell carcinoma . . . . . . . . . . . . . . . . . . 3.3.3. Myocardial infarction . . . . . . . . . . . . . . . . . 3.3.4. Heart transplantation . . . . . . . . . . . . . . . . . . 3.3.5. Atherosclerosis . . . . . . . . . . . . . . . . . . . . . 3.4. Conclusion . . . . . . . . . . . . . . . . . . . . . . . . . . 3.5. Bibliography . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Chapter 4. Corrosion and Erosion Monitoring of Pipes by an Ultrasonic Guided Wave Method. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Geir INSTANES, Mads TOPPE, Balachander LAKSHMINARAYAN, and Peter B. NAGY 4.1. Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.2. Ultrasonic guided wave monitoring of average wall thickness in pipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.2.1. Guided wave inspection with dispersive Lamb-type guided modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.2.2. Averaging in CGV inspection . . . . . . . . . . . . . . . . . 4.2.3. The influence of gating, true phase angle . . . . . . . . . . . 4.2.4. Temperature influence on CGV guided wave inspection . 4.2.5. Inversion of the average wall thickness in CGV guided wave inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.2.6. Additional miscellaneous effects in CGV guided wave inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.2.6.1. Fluid loading effects on CGV inspection . . . . . . . . . 4.2.6.2. Surface roughness effects on CGV inspection . . . . . . 4.2.6.3. Pipe curvature effects on CGV inspection . . . . . . . . 4.3. Experimental validation . . . . . . . . . . . . . . . . . . . . . . . 4.3.1. Laboratory tests . . . . . . . . . . . . . . . . . . . . . . . . . . 4.3.2. Field tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.4. Conclusion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.5. Bibliography . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ix 91 95 98 99 99 103 104 106 107 112 112 115 . . . . . 115 . . . . . 118 . . . . . . . . 119 123 129 132 . . . . . 134 . . . . . . . . . 136 136 139 141 145 145 151 153 155 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Chapter 5. Modeling of the Ultrasonic Field of Two Transducers Immersed in a Homogenous Fluid Using the Distributed Point Source Method . . . . 159 Rais AHMAD, Tribikram KUNDU and Dominique PLACKO 5.1. Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.2. Theory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159 160