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Comparative Study of Nonlinear Acoustic and Lamb Wave Techniques For Fatigue Crack Detection in Metallic Structures
Comparative Study of Nonlinear Acoustic and Lamb Wave Techniques For Fatigue Crack Detection in Metallic Structures
Comparative Study of Nonlinear Acoustic and Lamb Wave Techniques For Fatigue Crack Detection in Metallic Structures
A B S T R A C T The paper deals with fatigue crack detection in metallic structures. A simple fatigue
INTRODUCTION
Many different techniques based on ultrasonic wave propagation have been developed for fatigue crack detection.1,2 Ultrasonic testing, used in non-destructive testing
and evaluation (NDT/E), utilizes linear amplitude, phase
variations, mode conversion and energy partitioning of
reflected, transmitted or scattered high-frequency bulk
waves propagating through the thickness of monitored
specimens. The method is well established and widely
used in practice. In fact, it is the most versatile technique
used in industrial applications for over 60 years.
Lamb wave inspection is the most widely used damage detection technique utilizing ultrasonic-guided waves.
The method is based on Lamb waves propagating in platelike structures. The long-range inspection capability is
the major attraction of this technique for structural damage detection. The first application of Lamb waves for
damage detection goes back to 1950s.3 Despite the fact
that significant theoretical and experimental laboratory
experience has been gathered in this area of research over
many years, successful industrial applications are very limited. The complex wave propagation mechanism of Lamb
waves is one of the major difficulties. The subtleties of
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THEORETICAL BACKGROUND
In what follows, a brief introduction to nonlinear acoustics and Lamb wave inspection is given. For more details
related to theoretical background, damage detection implementation and application examples, the readers are
guided to relevant literature.
Nonlinear acoustics for crack detection
The nonlinear acoustic technique can be introduced using a simple example presented in Fig. 1. The procedure
used in most studies to date begins with introducing a
high-frequency ultrasonic (acoustic) wave travelling between two transducers mounted on the specimen. A second form of excitation (vibration/modal) is introduced,
the frequency of which is much lower than for the ultra-
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sonic wave. The low-frequency excitation is typically introduced with a hammer, mechanical shaker or ultrasonic
transducers.1022 The two different excitation signals are
run simultaneously in order to create the modulation effects. The output signal from the receiving transducer is
often analyzed in the frequency domain. In theory, while
the specimen is still intact the power spectrum shows the
fundamental acoustic harmonic at the exact frequency of
the ultrasonic wave. However, once a defect exists several
nonlinear effects can be observed. Often the amplitude
of the fundamental harmonic will decrease, its frequency
will be shifted, higher harmonics will appear but more noticeable will be the appearance of side bands or side lobes
around the fundamental harmonic, as reported in Refs
[1022]. These effects are the focal points of the nonlinear acoustic techniques used for damage detection. The
assumption is that nonlinear effects are due to damage and
that the structure does not contain any sources of nonlinearity. As damage to the specimen increases the nonlinear
effects will increase in intensity. It is important to note
that the combined vibro-acoustic interaction leading to
nonlinear effects is not related to a well-know nonlinear
breathing crack phenomenon that is not sensitive enough
to manifest itself in vibration/modal characteristics. However, the physical understanding of this interaction is still
not well understood and a number of different theoretical
explanations can be found in the literature, as summarized
in Ref.[19].
Different methods are used for the generation of acoustic and vibration signals; recent advancements in this
area include the use of low-profile piezoceramic transducers.27 The work described in this paper follows this
development.
Ultrasonic
signal
Modal excitation
Amplitude
Undamaged Specimen
Frequency
Damage
Cracked Specimen
Amplitude
Monitored specimen
Frequency
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M . R Y L E S et al .
EXPERIMENTAL INVESTIGATIONS
Lamb wave
structure
Fig. 3 Illustration of Lamb wave inspection.
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677
Sweep sine
Response signal
1.5
Amplitude (V)
Amplitude (V)
1
0.5
0
-0.5
-1
-1.5
0.82
0.87
0.92
0.97
1.02
0.025
0.02
0.015
0.01
0.005
0
-0.005
-0.01
-0.015
-0.02
-0.025
0
0.2
Time (s)
0.4
0.6
0.8
Time (s)
The frequency response function, calculated in MATLAB using the input and output signals, is given in
Fig. 6. This reveals a number of vibration modes of the
plate. The 118 Hz frequency mode was used in the nonlinear acoustic test for the low-frequency excitation. This
frequency corresponded approximately to the theoretical
value of the first bending mode of the plate.
Having decided upon the low-frequency excitation the
initial, that is, no crack damage detection data, were obtained following the procedures described in the previous
section.
Fatigue tests
In order to initiate and propagate a crack in the plate,
fatigue testing was used. The plate was fatigued using
an ESH hydraulic testing machine, as shown in Fig. 7.
The specimen was placed under a maximum combined
dynamic and static loading of 27 kN. The frequency of
excitation was equal to 10 Hz. The loading format was
kept to a tensiletensile format to make sure the specimen
did not buckle. A simple calculation was performed in
order to estimate the required dynamic loading. Initially
the load was set to a relatively low level to make sure the
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Amplitude
0.1
0.01
0.001
200
400
600
800
1000
1200
Frequency
60.0
50.0
40.0
30.0
20.0
10.0
0.0
500000
550000
600000
650000
700000
Number of Cycles
Fig. 8 Crack propagation curve.
Experimental set-up
specimen would not fail in the early stages. The load was
then increased to just above the calculated level. After the
crack had reached a certain length the loading was reduced
again to ensure the specimen did not fail completely.
The crack was observed using a 15 magnification and
measured using a steel ruler accurate to 0.5 mm. The first
crack was spotted at 535 000 cycles at a length of 1.0 mm.
The specimen was fatigued up to 674 500 cycles. Figure 8
shows the crack propagation curve. The maximum crack
observed was 51.5 mm, as shown in Fig. 9.
After subsequent crack length measurements, the specimen was unclamped for nonlinear acoustic and Lamb
wave tests, as described in the next section.
The set-up of the equipment used to monitor the specimen for fatigue cracks is shown in Fig. 10. A two-channel
TTi-TGA 1242, 40 MHz arbitrary waveform generator
was used to generate all signals, that is, low-frequency
harmonic vibration, high-frequency acoustic sine wave
and Lamb waves. The PI E-505 LVPZT piezo-amplifier
was used to amplify the vibration signal from the waveform generator. This signal was used to drive the piezoceramic stack actuator. In order to set and monitor the
DC offset of the amplifier, a voltage meter was used ensuring the stack actuator was not overloaded. To display
and store the response waveforms, a four-channel LeCroy
Waverunner LT264, 350, MHz, 1 GS/s digital oscilloscope was used.
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679
Fig. 9 Photograph for the 51.8 mm crack after 675 800 fatigue
cycles.
The five-cycle burst signal was used to excite the piezoceramic actuator A. The Haning window enveloped was
used. The peak-to-peak amplitude of the wave was equal
to 10 V. The frequency of the signal was equal to 75 kHz.
Following the aluminium dispersion curve in Fig. 2, this
frequency was chosen to obtain the so-called single Lamb
wave mode propagation. The frequency was selected experimentally to maximize the amplitude of the A 0 mode
and minimize to negligible levels the amplitude of the S 0
mode. The selected Lamb wave frequency was relatively
closed to the frequency of the ultrasonic wave used in
the nonlinear acoustic tests. Lamb wave responses were
sensed by the piezoceramic sensor B.
CRACK DETECTION RESULTS
Nonlinear acoustics
Figure 11 shows examples of power spectra for three different damage conditions. Here, the right column demonstrates the spectra that were obtained for the acoustic
responses gathered in the presence of the low-frequency
vibration signal. Similar spectra for the acoustic responses
obtained when the plate was not vibrated (i.e. the amplitude level of the low-frequency vibration was equal to
0 V) are given in the left column for comparison. The
ultrasonic carrier frequency of 60 kHz can be observed
in all presented spectra. A pattern of sidebands around
the carrier frequency can be seen in Fig. 11b and c additionally when the 1mm and 12 mm cracks were observed
in the plate and the plate was vibrated. The frequency
spacing of these sidebands corresponds to the 118 Hz frequency of the low-frequency vibration excitation. The results in Fig. 11b and c also demonstrate that the number of
sidebands depends on the crack length. Clearly, modulation sidebands indicated the presence of the crack in the
specimen.
Various parameters can be used to analyze the modulation processes resulting from the combined vibro-acoustic
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(a)
20V
-10
-10
-20
-20
Amplitude (dB)
Amplitude (dB)
0V
-30
-40
-50
-60
-40
-50
-60
-70
-70
-80
50000
-30
55000
60000
65000
Frequency (Hz)
-80
50000
70000
55000
60000
65000
Frequency (Hz)
70000
(b)
20V
-10
-10
-20
-20
Amplitude (dB)
Amplitude (dB)
0V
-30
-40
-50
-60
-40
-50
-60
-70
-70
-80
50000
-30
55000
60000
65000
Frequency (Hz)
-80
50000
70000
55000
60000
65000
Frequency (Hz)
70000
(c)
20V
0
-10
-10
-20
-20
-30
-40
-50
-60
-80
50000
55000
60000
65000
Frequency (Hz)
f
100%
f0
-30
-40
-50
-60
-70
-70
(1)
-80
50000
70000
55000
60000
65000
Frequency (Hz)
70000
1.2
Normalized damage index DI1
Amplitude (dB)
Amplitude (dB)
0V
0.8
0.6
0.4
0.2
0
0
2e+05
4e+05
Fatigue cycles
6e+05
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DI2 =
Rxy
Rxx Ryy
(2)
where
Rxy ( ) =
1.2
Normalized damage index DI2
There are several signal features that can be used to describe the severity of damage that the Lamb wave analysis
detects.1 This study utilizes the damage index based on
the frequency of the Lamb wave response in order to
be compatible with the nonlinear acoustics analysis. The
damage index DI 2 used was defined as
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0.8
0.6
0.4
0.2
1
T
T/2
x(t)y(t + )d t,
(3)
2e+05
T/2
is the cross-correlation function between the x(t) reference Lamb wave response representing the no damage
condition (i.e. the first measurement taken before the
specimen was fatigue cycled) and the y(t) actual Lamb
wave response and R xx , R yy are relevant autocorrelation
functions.
The assumption is that the cross-correlation detects any
alterations in frequency/phase of the analyzed signal that
might be caused by the damage. Equation (1) guarantees that if the frequency/phase of the two compared signals is identical (for no damage condition), the value of
the damage index DI 2 is equal to 0. If however, the frequency/phase is not the same then the cross-correlation
is less than 1 and the damage index increases with the
severity of damage and is normalized between 0 and 1.
Figure 14 presents damage index results plotted versus
fatigue cycles.
Discussion
The results, presented in Figs 12 and 14, were normalized in relation to their values at the severest damage state
to allow for direct comparison. Substantial scatter can
be observed due to the fact that the power spectra and
Lamb wave responses were not averaged. Nevertheless
clear trends can be observed in the behaviour of the analyzed damage indices; damage indices increase with the
number of cycles when the crack is observed.
The damage index DI 1 for the nonlinear acoustics tests
is scattered between 0 and approximately 0.22 for fatigue
cycles less than 300 000. Then the value goes up to 0.3 and
0.35 for 375 000 and 460 000 cycles, respectively. When
the first 1.0 mm crack is observed for 535 000 cycles, the
value of damage index increases to 0.4 and then grows
rapidly with the large scatter.
The first 10 values of damage index (i.e. up to 275 000
fatigue cycles) from the no damage condition (i.e. crack
not present in the specimen) were used to establish the
level of scatter; the mean 0 and standard deviation 0
were calculated. The alarm or warning level was calculated as 0 +4 0 23 to obtain information about possible damage. This alarm level is shown in Fig. 12 as the
straight solid line. Once the damage index reaches the
alarm level, it is assumed that the crack is detected. The
analysis performed shows that 1 mm crack is detected after
535 000 fatigue cycles when the nonlinear acoustic is used
for crack detection. This result can be confirmed by the
(b)
30
20
20
Amplitude [mV]
Amplitude [mV]
(a)
10
0
-10
-20
10
0
-10
-20
0.2
0.4
Time [ms]
0.6
6e+05
30
-30
0
4e+05
Fatigue Cycles
-30
0
0.2
0.4
Time [ms]
Fig. 13 Lamb wave responses for after: (a) 0 fatigue cycles (b) 535 00 fatigue cycles.
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CONCLUSIONS
tigated. Although, the smallest crack observed was manifested by the steady increase of damage index applied,
statistical analysis could not be used to support damage
detection. This is due to the settling-in period observed
for the damage index representing the no damage condition. Additionally, the value of damage index, reached for
the smallest crack observed, stayed relatively unchanged
until the crack length reached 12 mm.
Further investigations are required to confirm the findings. The study should investigate various parameters
used for damage detection including amplitude and frequency of ultrasonic (acoustic and Lamb wave) and vibration excitation and signal features used to detect cracks.
The effect transducer position and signal averaging in
the time and frequency domain should also be investigated. More statistical tests of the undamaged data need
to be performed to establish appropriate confidence levels for damage parameters indicating cracks. In practical
applications, it is also important to use more efficient
piezoelectric-based low-frequency excitation method in
nonlinear acoustics Clamped and/or blocked condition
of the actuator with a counter-mass used would certainly
increased the strain level applied.
Acknowledgements
The authors would like to thank Mr. John Goodliffe and
Mr. Richard Kay from Sheffield University for technical
assistance in fatigue analysis.
REFERENCES
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3 Worlton, D. C. (1957) Ultrasonic testing with Lamb waves.
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Optimization of Lamb wave methods for damage detection
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