Modeling and Experimental Analysis of Roughness Effect on Ultrasonic Nondestructive Evaluation of Micro-crack

Abstract A high-precision evaluation of ultrasonic detection sensitivity for a micro-crack can be restricted by a corroded rough surface when the surface microtopography is of the same order of magnitude as the crack depth. In this study, a back-surface micro-crack is considered as a research target...

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Autores principales:	Zhe Wang, Zhichao Fan, Xuedong Chen, Yihua Kang, Jingwei Cheng, Wei Chen
Formato:	article
Lenguaje:	EN
Publicado:	SpringerOpen 2021
Materias:	Surface roughness Micro-crack Ultrasonic testing model Detection accuracy Evaluation method Ocean engineering TC1501-1800 Mechanical engineering and machinery TJ1-1570
Acceso en línea:	https://doaj.org/article/d94b3ffe71f44856aef1dc391a5f6493
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spelling	oai:doaj.org-article:d94b3ffe71f44856aef1dc391a5f64932021-11-28T12:03:34ZModeling and Experimental Analysis of Roughness Effect on Ultrasonic Nondestructive Evaluation of Micro-crack10.1186/s10033-021-00637-51000-93452192-8258https://doaj.org/article/d94b3ffe71f44856aef1dc391a5f64932021-11-01T00:00:00Zhttps://doi.org/10.1186/s10033-021-00637-5https://doaj.org/toc/1000-9345https://doaj.org/toc/2192-8258Abstract A high-precision evaluation of ultrasonic detection sensitivity for a micro-crack can be restricted by a corroded rough surface when the surface microtopography is of the same order of magnitude as the crack depth. In this study, a back-surface micro-crack is considered as a research target. A roughness-modified ultrasonic testing model for micro-cracks is established based on a multi-Gaussian beam model and the principle of phase-screen approximation. The echo signals of micro-cracks and noises corresponding to different rough front surfaces and rough back surfaces are obtained based on a reference reflector signal acquired from a two-dimensional simulation model. Further comparison between the analytical and numerical models shows that the responses of micro-cracks under the effects of different corroded rough surfaces can be accurately predicted. The numerical and analytical results show that the echo signal amplitude of the micro-crack decreases significantly with an increase in roughness, whereas the noise amplitude slightly increases. Moreover, the effect of the rough front surface on the echo signal of the micro-crack is greater than that of the rough back surface. When the root-mean-square (RMS) height of the surface microtopography is less than 15 μm, the two rough surfaces have less influence on the echo signals detected by a focused transducer with a frequency of 5 MHz and diameter of 6 mm. A method for predicting and evaluating the detection accuracy of micro-cracks under different rough surfaces is proposed by combining the theoretical model and a finite element simulation. Then, a series of rough surface samples containing different micro-cracks are fabricated to experimentally validate the evaluation method.Zhe WangZhichao FanXuedong ChenYihua KangJingwei ChengWei ChenSpringerOpenarticleSurface roughnessMicro-crackUltrasonic testing modelDetection accuracyEvaluation methodOcean engineeringTC1501-1800Mechanical engineering and machineryTJ1-1570ENChinese Journal of Mechanical Engineering, Vol 34, Iss 1, Pp 1-12 (2021)
institution	DOAJ
collection	DOAJ
language	EN
topic	Surface roughness Micro-crack Ultrasonic testing model Detection accuracy Evaluation method Ocean engineering TC1501-1800 Mechanical engineering and machinery TJ1-1570
spellingShingle	Surface roughness Micro-crack Ultrasonic testing model Detection accuracy Evaluation method Ocean engineering TC1501-1800 Mechanical engineering and machinery TJ1-1570 Zhe Wang Zhichao Fan Xuedong Chen Yihua Kang Jingwei Cheng Wei Chen Modeling and Experimental Analysis of Roughness Effect on Ultrasonic Nondestructive Evaluation of Micro-crack
description	Abstract A high-precision evaluation of ultrasonic detection sensitivity for a micro-crack can be restricted by a corroded rough surface when the surface microtopography is of the same order of magnitude as the crack depth. In this study, a back-surface micro-crack is considered as a research target. A roughness-modified ultrasonic testing model for micro-cracks is established based on a multi-Gaussian beam model and the principle of phase-screen approximation. The echo signals of micro-cracks and noises corresponding to different rough front surfaces and rough back surfaces are obtained based on a reference reflector signal acquired from a two-dimensional simulation model. Further comparison between the analytical and numerical models shows that the responses of micro-cracks under the effects of different corroded rough surfaces can be accurately predicted. The numerical and analytical results show that the echo signal amplitude of the micro-crack decreases significantly with an increase in roughness, whereas the noise amplitude slightly increases. Moreover, the effect of the rough front surface on the echo signal of the micro-crack is greater than that of the rough back surface. When the root-mean-square (RMS) height of the surface microtopography is less than 15 μm, the two rough surfaces have less influence on the echo signals detected by a focused transducer with a frequency of 5 MHz and diameter of 6 mm. A method for predicting and evaluating the detection accuracy of micro-cracks under different rough surfaces is proposed by combining the theoretical model and a finite element simulation. Then, a series of rough surface samples containing different micro-cracks are fabricated to experimentally validate the evaluation method.
format	article
author	Zhe Wang Zhichao Fan Xuedong Chen Yihua Kang Jingwei Cheng Wei Chen
author_facet	Zhe Wang Zhichao Fan Xuedong Chen Yihua Kang Jingwei Cheng Wei Chen
author_sort	Zhe Wang
title	Modeling and Experimental Analysis of Roughness Effect on Ultrasonic Nondestructive Evaluation of Micro-crack
title_short	Modeling and Experimental Analysis of Roughness Effect on Ultrasonic Nondestructive Evaluation of Micro-crack
title_full	Modeling and Experimental Analysis of Roughness Effect on Ultrasonic Nondestructive Evaluation of Micro-crack
title_fullStr	Modeling and Experimental Analysis of Roughness Effect on Ultrasonic Nondestructive Evaluation of Micro-crack
title_full_unstemmed	Modeling and Experimental Analysis of Roughness Effect on Ultrasonic Nondestructive Evaluation of Micro-crack
title_sort	modeling and experimental analysis of roughness effect on ultrasonic nondestructive evaluation of micro-crack
publisher	SpringerOpen
publishDate	2021
url	https://doaj.org/article/d94b3ffe71f44856aef1dc391a5f6493
work_keys_str_mv	AT zhewang modelingandexperimentalanalysisofroughnesseffectonultrasonicnondestructiveevaluationofmicrocrack AT zhichaofan modelingandexperimentalanalysisofroughnesseffectonultrasonicnondestructiveevaluationofmicrocrack AT xuedongchen modelingandexperimentalanalysisofroughnesseffectonultrasonicnondestructiveevaluationofmicrocrack AT yihuakang modelingandexperimentalanalysisofroughnesseffectonultrasonicnondestructiveevaluationofmicrocrack AT jingweicheng modelingandexperimentalanalysisofroughnesseffectonultrasonicnondestructiveevaluationofmicrocrack AT weichen modelingandexperimentalanalysisofroughnesseffectonultrasonicnondestructiveevaluationofmicrocrack
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Modeling and Experimental Analysis of Roughness Effect on Ultrasonic Nondestructive Evaluation of Micro-crack

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