Real-time 3D imaging with Fourier-domain algorithms and matrix arrays applied to non-destructive testing

An efficient ultrasonic wavenumber-domain plane wave imaging method towards the inspection of curved structures

Ultrasonic phased array testing is commonly employed for inspecting curved structures. Conventional plane wave imaging techniques, based on delay-and-sum in the time-domain, offer high image quality and inspection accuracy but suffer from low frame rates due to their high computational complexity. In this work, an efficient wavenumber-domain imaging method that combines non-stationary wavefield extrapolation and f-k migration is proposed for curved structure inspection. Special emission focal laws are designed to generate a sequence of steered plane waves through the curved interface. The raw data is then extrapolated to the top boundary of the region of interest, followed by f-k migration to reconstruct images with high time efficiency. Simulation and experimental evaluations demonstrate a time reduction by a factor of up to 32.24 compared to conventional time-domain plane wave image reconstruction with equivalent image quality, highlighting its potential for monitoring flaws in real-time.

Propagation of elastic waves in correlated dispersions of resonant scatterers

The propagation of coherent longitudinal and transverse waves in random distributions of spherical scatterers embedded in an elastic matrix is studied. The investigated frequency range is the vicinity of the resonance frequencies of the translational and rotational motion of the spheres forced by the waves, where strong dispersion and attenuation are predicted. A technique for making samples made of layers of carbide tungsten beads embedded in epoxy resin is presented, which allows control of the scatterers distribution, induce short-range positional correlations, and minimize the anisotropy of samples. Comparison between phase velocity and attenuation measurements and a model based on multiple scattering theory (MST) shows that bulk effective properties accurately described by MST are obtained from three beads layers. Besides, short-range correlations amplify the effect of mechanical resonances on the propagation of longitudinal and transverse coherent waves. As a practical consequence, the use of short-range positional correlations may be used to enhance the attenuation of elastic waves by disordered, locally resonant, elastic metamaterials, and MST globally correctly predicts the effect of short-range positional order on their effective properties.

Fourier-Based Fast 3-D Ultrasound Imaging Using Row-Column-Addressed 2-D Arrays

A Fourier-based fast 3-D ultrasound imaging method using row-column-addressed (RCA) 2-D arrays is presented. The row elements in an RCA array are activated sequentially, and all the column elements are used to receive. The obtained dataset is adapted to approximate to that obtained using a fully sampled array after a plane wave at a given incident angle is transmitted. In this way, the fast algorithm in plane-wave Fourier imaging (PWFI) can be applied to the adapted dataset. In addition, synthesizing multiple datasets based on multiple incident angles enables angular compounding, which improves the image quality. The proposed method was validated using computer simulations and physical-phantom experiments. The results show that the spatial resolution and contrast of the proposed method are comparable with those of its PWFI counterpart without requiring a fully sampled (FS) array. Compared with the delay-and-sum (DAS) method using the RCA array, the proposed method provides comparable spatial resolution but lower contrast; however, the computational complexity is significantly reduced from O(N4Nz) to O(WN2Nz log2(N2Nz)) , where N is the number of elements on each side of the RCA array, Nz is the number of voxels in the axial direction in the output image, and W is the number of compounding angles. For example, in the simulated results when the maximum compounding angle M is 5°, at a given point the lateral - 6-dB width provided by the proposed method is 0.241 mm (0.267 mm for DAS), the contrast ratio of a hyperechoic cyst is 8.87 dB (9.10 dB for DAS), the number of real number operations is reduced by a factor of 20.62, and the number of memory accesses is reduced by a factor of 47.21, both compared with DAS. This novel fast algorithm could facilitate the development of compact real-time 3-D imaging systems, especially when the channel count is high and a large field of view (FOV) is required.

Ultrasonic testing of thick and thin Inconel 625 alloys manufactured by laser powder bed fusion

Additive manufacturing of alloys enables low-volume production of functional metallic components with complex geometries. Ultrasonic testing can ensure the quality of these components and detect typical defects generated during laser powder bed fusion (LPBF). However, it is difficult to find a single ultrasonic inspection technique that can detect defects in the large variety of geometries generated using LPBF. In this work, phased array ultrasonic testing (PAUT) is suggested to inspect thick LPBF components, while guided waves are explored for thin curved ones. PAUT is used to detect cylindrical lack of fusion defects in thick LPBF rectangular parts. Practical defects are generated by reducing the laser power at prespecified locations in the samples. The defects' shape and density are verified using optical microscopy and X-ray computed tomography. Partially fused defects down to 0.25 mm in diameter are experimentally detected using a 10 MHz PAUT probe with the total focusing method post-processing. The experimental results are compared to defect images predicted by finite element simulations. For thin components with curved geometry, guided waves are used to detect powder-filled cylindrical defects. The waves are generated using piezoelectric transducers, and the spatiotemporal wavefield is measured using a scanning laser Doppler vibrometer. Using root-mean-square imaging of the wavefield, defects down to 1 mm are clearly detected despite the complex internal features in the samples.