Investigation of synthetic aperture methods in ultrasound surface imaging using elementary surface types

Probe Standoff Optimization Method for Phased Array Ultrasonic TFM Imaging of Curved Parts

The reliability of the ultrasonic phased array total focusing method (TFM) imaging of parts with curved geometries depends on many factors, one being the probe standoff. Strong artifacts and resolution loss are introduced by some surface profile and standoff combinations, making it impossible to identify defects. This paper, therefore, introduces a probe standoff optimization method (PSOM) to mitigate such effects. Based on a point spread function analysis, the PSOM algorithm finds the standoff with the lowest main lobe width and side lobe level values. Validation experiments were conducted and the TFM imaging performance compared with the PSOM predictions. The experiments consisted of the inspection of concave and convex parts with amplitudes of 0, 5 and 15 λ_Al, at 12 standoffs varying from 20 to 130 mm. Three internal side-drilled holes at different depths were used as targets. To investigate how the optimal probe standoff improves the TFM, two metrics were used: the signal-to-artifact ratio (SAR) and the array performance indicator (API). The PSF characteristics predicted by the PSOM agreed with the quality of TFM images. A considerable TFM improvement was demonstrated at the optimal standoff calculated by the PSOM. The API of a convex specimen’s TFM was minimized, and the SAR gained up to 13 dB, while the image of a concave specimen gained up to 33 dB in SAR.

Floquet wave theory-based time-corrected ultrasonic total focusing method for fiber-reinforced composite laminate

Fiber reinforced polymers (FRPs) are increasingly used in thick primary load-bearing structures. Nevertheless, manufacturing and in-service defects occur with a higher chance as the FRP thickness increases and thus the potential structure defects should be detected and evaluated. To image defects in thick FRP over 10 mm thick, this study proposes a frequency-and-structure dependent time-corrected ultrasonic total focusing method (FS-TFM) based on Floquet wave theory, which differs from conventional TFM that the wave velocity correction along different propagation direction bases on not only the structural anisotropy and inhomogeneity of FRP, but also on the probing frequency. First an analytical Floquet-wave-based dynamic homogenization for a crossply FRP laminate is performed, to obtain the homogenization region and then the wave anisotropy and dispersion therein. Then numerical finite element analysis follows, to further interrogate the time domain feature of wave signals. With the understanding of wave propagation, by accurately correcting the wave velocity anisotropy related to both the inspected crossply FPR and wave frequency, the FS-TFM imaging technique is proposed to focus the defect-scattered wave energy on the defect location. In addition, the signal-to-noise ratio (SNR) analysis of side-drilled-hole (Ø2 mm) imaging via different imaging algorithms shows that the proposed FS-TFM achieves the highest SNR at the frequency approaching the upper limit of the homogenization region. Finally, the experimental validation further indicates the potential of the proposed FS-TFM for accurate defect imaging in thick FRP.

Accurate 3D reconstruction of bony surfaces using ultrasonic synthetic aperture techniques for robotic knee arthroplasty

Robotically guided knee arthroplasty systems generally require an individualized, preoperative 3D model of the knee joint. This is typically measured using Computed Tomography (CT) which provides the required accuracy for preoperative surgical intervention planning. Ultrasound imaging presents an attractive alternative to CT, allowing for reductions in cost and the elimination of doses of ionizing radiation, whilst maintaining the accuracy of the 3D model reconstruction of the joint. Traditional phased array ultrasound imaging methods, however, are susceptible to poor resolution and signal to noise ratios (SNR). Alleviating these weaknesses by offering superior focusing power, synthetic aperture methods have been investigated extensively within ultrasonic non-destructive testing. Despite this, they have yet to be fully exploited in medical imaging. In this paper, the ability of a robotic deployed ultrasound imaging system based on synthetic aperture methods to accurately reconstruct bony surfaces is investigated. Employing the Total Focussing Method (TFM) and the Synthetic Aperture Focussing Technique (SAFT), two samples were imaged which were representative of the bones of the knee joint: a human-shaped, composite distal femur and a bovine distal femur. Data were captured using a 5MHz, 128 element 1D phased array, which was manipulated around the samples using a robotic positioning system. Three dimensional surface reconstructions were then produced and compared with reference models measured using a precision laser scanner. Mean errors of 0.82mm and 0.88mm were obtained for the composite and bovine samples, respectively, thus demonstrating the feasibility of the approach to deliver the sub-millimetre accuracy required for the application.