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Investigation On Novel Embedded Piezoelectric Ultrasonic Transducers For Corrosion Monitoring of Reinforced Concrete
Investigation On Novel Embedded Piezoelectric Ultrasonic Transducers For Corrosion Monitoring of Reinforced Concrete
Investigation On Novel Embedded Piezoelectric Ultrasonic Transducers For Corrosion Monitoring of Reinforced Concrete
PAPER
Abstract
The corrosion monitoring of reinforced concrete is important for the structural safety. A kind of
embedded annular piezoelectric ultrasonic transducers suitable for corrosion monitoring of the
reinforced concrete were proposed and fabricated, and the electrical impedance spectra and ultrasonic
pitch-catch characteristic of the transducers in the steel rebar were discussed. The results show that
after the annular piezoceramic disk was encapsulated, the resonance of the piezoelectric ceramic
under effects of electric excitation was restricted due to the damping effect of the packaging layer.
Comparing with the annular piezoelectric ceramic disk, the wall thickness extensional resonance
frequency of the annular ultrasonic transduces decreases, however, the corresponding frequency
bandwidth increases. The ultrasonic pitch-catch experimental results indicate that the annular full-
electrode transducer has the largest wave duration time and the minimum head wave amplitude than
others, but the annular serial transducer has the largest head wave amplitude and peak to peak value.
When the excitation frequency of the signal is in the range of 100–160 kHz, the annular serial
transducer has the best ability to receive the ultrasonic wave. A good distinguishability of the
longitudinal and flexural wave can be obtained in the reception waveform when the distance between
the emission and reception transducers is larger than 600 mm in a long round steel rebar.
to the inspection and protection of reinforced concrete. Pre- piezoelectric ultrasonic transducer based on the structural
sently, the popular corrosion monitoring methods of the steel design of the annular piezoelectric ceramic. The electrical
rebar include electrochemical detection technique [8–10], ultra- impedance spectra of the transducers before and after
sonic inspection technique [11–13], acoustic emission detection encapsulation were investigated, and meanwhile the ultra-
technique [14, 15], and resistance and electromagnetic techni- sonic pitch-catch characteristics of the transducers in the steel
ques [16–18] etc. Zhao et al [19, 20] investigated the steel rebar rebar were also discussed.
corrosion monitoring technique for steel reinforced concrete
structures by using the fiber optical Brillouin sensing technique
and fiber optical white light interferometer sensing technique. 2. Experiments
Talakokula et al [21] investigated the carbonation induced cor-
rosion initiation and progression in reinforced concrete structures 2.1. Theoretical background
by using piezo-impedance transducers. Li et al carried out many
researches on corrosion monitoring or reinforced concrete by Piezoelectric ceramic materials have been widely used in
using different advanced techniques [22–26]. For example, they many different fields due to their excellent piezoelectric
proposed a novel type of ferromagnetic distance-based metal effects which can be expressed as following equations [40].
loss sensor for quantitative measurement of the accumulated ⎧ D1 = d15 T5 + e1E1
amount of corrosion, and validated its metal loss measurement ⎪
⎨ D2 = d15 T4 + e2 E2 , (1 )
through scanning the fabricated corrosion samples [22]. In ⎪
⎩ D 3 = d33 T3 + d31(T1 + T2) + e3 E3
addition, they also conducted the experimental investigation on
corrosion monitoring of a steel reinforced mortar block through ⎧S = s E T + s E T + s E T + d E
combined acoustic emission, fiber Bragg grating strain mea- ⎪ 1 11 1 12 2 13 3 31 3
surement, carbon fiber, and fiber Bragg grating active thermal ⎪ S2 = s11E T2 + s12E T1 + s13E T3 + d31E3
⎪
⎪ S3 = s E T3 + s E (T1 + T2) + d33 E3
probe technique etc, and found a good correlation between ⎨ 33 13 , (2 )
acoustic emission activity and expansive strain measured on the ⎪ S4 = s44
E
T4 + d15 E2
specimen surface, and corrosion severity and magnitude of the ⎪
⎪ S5 = s44 T5 + d15 E1
E
temperature response [23, 24]. ⎪
Towards the development of a noninvasive, in situ, and ⎩ S6 = s66 T6
nondestructive corrosion monitoring methodology, ultrasonic where symbols d and ε mean the piezoelectric strain constant
wave approach was especially studied due to the capability of and dielectric constant. Symbols D, E, S, T, and sE mean the
testing over long distances with a sensitivity often greater electrical displacement, electrical field, strain, stress and
than the conventional nondestructive testing techniques [27]. elastic compliance coefficient at a constant electrical field.
The piezoelectric transducer is the core part of ultrasonic The subscript 3 denotes the polarization axis, and subscripts 1
monitoring technique, which plays a great role to ensure the and 2 are the arbitrary orthogonal axes perpendicular to the
monitoring reliability of structures [28, 29]. Presently, the polarization axis. The subscripts 4, 5 and 6 denote the in-
commercial ultrasonic transducers encapsulated with metallic plane shearing stress and strain perpendicular to the axes of 1,
shells are not suitable for the long-term corrosion monitoring 2 and 3, respectively.
of the steel rebar, and are also easily corroded when It is known that the piezoelectric materials can produce
embedded into concrete. Hence, there is a need for non- induction charge under effect of stress wave due to direct
intrusive, in situ, and real time corrosion monitoring trans- piezoelectric effect (equation (1)), and the ultrasonic reception
ducers for reinforced concrete structures. Recently, the transducer can therefore be tailored by using this advantage.
research of embedded piezoelectric transducers for non- On the other hand, when the alternating current is applied to
destructive evaluation of the concrete has become increas- the piezoelectric materials, the piezoelectric materials will
ingly popular [30–35]. Luo et al [36] conducted the concrete have tiny deformation due to the converse piezoelectric effect
infill monitoring in concrete-filled FRP tubes by using a PZT- (equation (2)) caused by electrical polarization. Therefore, the
based ultrasonic time-of-flight method and experimentally emission type piezoelectric ultrasonic transducers can also be
validated numerical findings. Liu et al [37] investigated the fabricated by using the converse piezoelectric effect.
ultrasonic characteristic of the piezoelectric smart aggregates The ultrasonic wave is a mechanical wave, which is also
under effects of axial compressive loading, and provides a called as the ultrasonic guided wave due to effects of the
potential method to assess stress state in concrete structures boundary condition when it transmits in the medium with a
using smart aggregates. Li et al [38] used the smart aggre- finite boundary, such as thin plate, rod and shell. Here, the
gates as embedded AE sensors to detect and evaluate the long steel rebar can be assumed to be an infinite long elastic
damage of the concrete structure. Huo et al [39] carried out rod, and the ultrasonic transmission modes in the rebar can be
the steel bar corrosion monitoring by using a piezoceramic deduced by using the Navier motion equations in a cylindrical
transducer with time reversal method. However, as for the coordinate by setting Z axis along the axis direction of the
long-term corrosion monitoring requirement of reinforced rebar [41].
concrete, it is very important to develop an efficient embed-
ded piezoelectric transducer satisfying the shape feature ¶f 2m ¶wz ¶w ¶ 2u
(l + 2 m ) - + 2m q = r 2r , (3 )
of the rebar. Therefore, we proposed a novel embedded ¶r r ¶q ¶z ¶t
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Smart Mater. Struct. 28 (2019) 115041 P Liu et al
1 ¶f ¶w ¶w ¶ 2u
(l + 2 m ) - 2m r + 2m z = r 2q , (4 )
r ¶q ¶z ¶r ¶t
¶f 2 m ¶ ( r wq ) 2m ¶wr ¶ 2u
(l + 2 m ) - + = r 2z , (5 )
¶z r ¶r r ¶q ¶t
where symbol Φ is the volume constant of cylindrical coor-
dinate. Symbols ur, uθ and uz denote radial displacement, Figure 1. Layout schematic of the piezoelectric ultrasonic transdu-
circular displacement and axial displacement. Symbols ωr, ωθ cers on the steel rebar.
and ωz denote the different components of the rotation vector.
Symbols λ and μ are lame constant and Poisson’s ratio, and produce the ultrasonic wave, thus the PZT-4 type piezo-
symbols r and θ are radius and cross section angle of the electric ceramic block of 14×14×8 mm with a large
elastic rod. mechanical quality factor was used as the core element of the
1 ¶(rur ) 1 ¶uq ¶uz emission transducers, The annular PZT-5 type piezoelectric
f= + + , (6 )
r ¶r r ¶q ¶z ceramic disk of Φ16×Φ13×1.5 mm with a large piezo-
1 ¶uz ¶uq electric constant was used to fabricate the reception type
2w r = - , (7 ) ultrasonic transducer. In addition, the mixture of Portland
r ¶q ¶z
cement (42.5), epoxy resin, and hardening agent with a mass
¶ur ¶uz
2 wq = - , (8 ) ratio of 4:4:1 was used as the packaging material of the
¶z ¶r transducers. The detailed parameters of the PZT piezoelectric
1 ⎡ ¶(ruq ) ¶ur ⎤ ceramic are shown in table 1.
2 wz = ⎢ - ⎥. (9 )
r ⎣ ¶r ¶q ⎦ Note: fs and fp are the series and parallel resonant fre-
quencies of the PZT ceramics. kt is the thickness electro-
The stress components on the rod surface equal to zero, mechanical coupling coefficient, and d33 is the piezoelectric
that is,
strain constant, and Qm is the mechanical quality factor.
srr = srq = srz = 0. (10) Based on shape feature of the steel rebar, three kinds of
Therefore, the following equations can be obtained based reception type annular piezoelectric ultrasonic transducers
on the relationship of stress and strain. with different circuit connection modes were designed and
fabricated, which were termed as annular full-electrode
¶ur
srr = lf + 2m , (11) transducer, annular serial transducer, and annular parallel
¶r transducer, respectively. The advantage of the annular ultra-
⎡1 ¶ur ¶ ⎛ u ⎞⎤ sonic transducers is that they can easily be fixed on the steel
srq = m ⎢ + r ⎜ q ⎟ ⎥, (12)
⎣r ¶q ¶r ⎝ r ⎠ ⎦ rebar, in addition, because the contacting area between the
transducers and the steel rebar is large, the acoustic wave
¶ur ¶uz
srz = m ( + ). (13) transmitted through the steel rebar can also be effectively
¶z ¶r received by the transducers. The layout schematic of the
Then, the vibration equations of different directions can piezoelectric ultrasonic transducers on the steel rebar is shown
be deduced based on the boundary conditions of the rod, as in figure 1.
follows. The detailed fabrication process of the annular full-
ur = U (r ) cos (nq ) ei (kz - wt ) , (14) electrode transducers is as follows. The shielding wire was
welded on the inner and outer electrodes of the annular
uq = V (r ) sin (nq ) ei (kz - wt ) , (15) piezoelectric ceramic disk, respectively, and then a round
uz = W (r ) cos (nq ) ei (kz - wt ) , (16) stainless-steel bar coated with mold discharging agent was
inserted into the ceramic disk. The Portland 42.5 cement,
where symbols k, z, ω denote the wave number, propagation
epoxy resin, and hardening agent was mixed with a mass ratio
distance and angular frequency of the ultrasonic wave. n
of 4:4:1, which was vacuumized for 5 min to eliminate the
equals to zero or positive integer.
pores and then filled into the gap between the inner electrode
There exist obvious dispersion phenomena and multi-
surface of the ceramic disk and the steel bar. The outer
modal characteristic for the ultrasonic guided wave, such as
electrode surface of the ceramic disk was electrically insu-
longitudinal and torsional modes when n=0, and flexural
lated by using the silica gel. After solidifying, the stainless-
mode (n=1, 2, 3K). Therefore, the corrosion of the steel
rebar can be monitored based on the variation of ultrasonic steel bar was taken out from the ceramic disk, and the copper
guided wave by using the ultrasonic transducer. shielding net was coated on the silica gel layer. Finally, the
mixture of cement, epoxy resin, and hardening agent was
again used to package the copper shielding layer. The struc-
2.2. Fabrication of the piezoelectric ultrasonic transducers
tural schematic of the annular full-electrode ultrasonic trans-
Piezoelectric lead zirconate titanate (PZT) ceramics were used ducers is shown in figure 2(a).
as the core element of the piezoelectric ultrasonic transduces. As for the annular series and parallel transducers, the
Usually, the emission type ultrasonic transducers are used to annular piezoelectric ceramic disk was first cut to six parts
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Smart Mater. Struct. 28 (2019) 115041 P Liu et al
Figure 2. The structural schematic of the annular ultrasonic transducers (a) annular full-electrode transducer; (b) annular serial transducer; (c)
annular parallel transducer.
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Smart Mater. Struct. 28 (2019) 115041 P Liu et al
Figure 5. Impedance spectra of the piezoelectric ceramic and different ultrasonic transducers.
resonant peaks in figure 5(b) are weaker than those in applied to the round steel rebar by the electrochemical
figure 5(a). As for the annular serial and parallel ultrasonic workstation. Then, the corrosion rate of the steel rebar can be
transducers, the radial extensional resonant peak gets weaker calculated based on the current intensity and time, and mass
and even disappears in figure 5(c) because of the variation of loss rate of steel rebar before and after corrosion etc. The
the electric impedance parameters, nevertheless, the band- detailed corrosion method can also refer to our previous
width of the wall thickness extensional resonant peak report [10]. Figure 6 shows the photo of the annular ultrasonic
increases. Comparing with the annular piezoelectric ceramic transducers in the corroded steel rebar.
disk, the wall thickness extensional resonance frequency of all A full sine signal excited by the arbitrary function gen-
the annular ultrasonic transducers decreases, especially for the erators with an amplitude of 10 V and 1 ms time interval was
annular serial and parallel transducers. It should also be noted used to excite the emission transducers, and the time domain
that the impedance value of the annular serial ultrasonic spectra of the ultrasonic wave received by different ultrasonic
transducers is obviously larger than others due to the serial transducers at the steel rebar corrosion rates of 0%, 2%, 5%
electrically connection mode. are shown in figure 7. It can be seen that all the annular ultra-
sonic transducers can well receive the ultrasonic wave trans-
mitted through the corroded steel rebar. Based on the basic
3.2. Ultrasonic characteristics of the transducers in corroded
acoustic theory, it is known that the ultrasonic wave transmitted
steel rebar
through the medium is usually composed of various complex
The round steel rebar of Φ12×150 mm was used as the waves, and the first arrival wave is longitudinal wave, which can
testing objective. The emission transducers were affixed to be used intuitively to judge the structural heath condition. In
one end of the steel rebar, and the annular ultrasonic trans- comparison, the annular full-electrode transducer has the largest
ducers were affixed to the other end of the steel rebar, wave duration time and the minimum head wave amplitude than
respectively. The electrochemistry corrosion method was others. And the annular serial transducer has the largest head
employed to accelerate the corrosion of the steel rebar as wave amplitude and peak to peak value, while the annular
follows. The round steel rebar and a stainless-steel rebar were parallel transducer has the minimum peak to peak value.
placed in a container with 5% NaCl solution as the working In addition, it also can be seen that with increasing the
and auxiliary electrodes of the electrochemical work station, corrosion rate of the steel rebar, the head wave amplitude
respectively, and a current density of 1 (mA)cm−2 was shows an obvious decreasing trend, especially for the annular
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Smart Mater. Struct. 28 (2019) 115041 P Liu et al
6
Smart Mater. Struct. 28 (2019) 115041 P Liu et al
Figure 7. Time domain spectra of the ultrasonic wave received by different annular ultrasonic transducers at different steel rebar corrosion
rates. (a)–(c) annular full-electrode transducer; (d)–(f) annular serial transducer; (g)–(i) annular parallel transducer.
7
Smart Mater. Struct. 28 (2019) 115041 P Liu et al
Figure 10. Time domain spectra of the received ultrasonic wave excited at different frequencies.
Figure 11. Time domain spectra of the ultrasonic wave received by the annular serial transducer at different markers (Note: L and F modes
mean the wave packets of the longitudinal and flexural modes; LR and FR modes mean the reflection wave packets of the longitudinal and
flexural modes from the end of the steel rebar).
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Smart Mater. Struct. 28 (2019) 115041 P Liu et al
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This work was supported by National Key R&D Program of Sensors Actuators A 246 123–8
China (Grant no. 2017YFE0120900), Natural Science Out- [15] Abouhussien A A and Hassan A A A 2016 Detection of bond
standing Youth Foundation of Shandong Province (Grant no. failure in the anchorage zone of reinforced concrete beams
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ZR2017JL023), National Natural Science Foundation of 075034
China (Grant no. 51778632, U1434204 and 51408614), and [16] Legat A 2007 Monitoring of steel corrosion in concrete by
China Postdoctoral Science Foundation (grant numbers electrode arrays and electrical resistance probes Electrochim.
2016M600675 and 2017T100647). Acta 52 7590–8
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Provincial Key Laboratory of Durability for Marine Civil Engi- Actuators A 286 14–27
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Research on Science and technology program of Shenzhen corrosion in concrete using ground penetrating radar Corros.
(JCYJ20170818143541342 and JCYJ20180305123935198) and Sci. 114 123–32
Natural Science Foundation of Hunan Province of China [19] Zhao X F et al 2011 Brillouin corrosion expansion sensors for
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(2017JJ3385). winding method Sensors 11 10798–819
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Dongyu Xu https://orcid.org/0000-0001-5217-5417 corrosion initiation and progression in reinforced concrete
structures using piezo-impedance transducers Sensors
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