† Corresponding author. E-mail:
Project supported by the National Natural Science Foundation of China (Grant Nos. 61571222, 61602235, and 11474160) and the Six Talent Peaks Project of Jiangsu Province, China.
We propose a nonlinear ultrasonic technique by using the mixed-frequency signals excited Lamb waves to conduct micro-crack detection in thin plate structures. Simulation models of three-dimensional (3D) aluminum plates and composite laminates are established by ABAQUS software, where the aluminum plate contains buried crack and composite laminates comprises cohesive element whose thickness is zero to simulate delamination damage. The interactions between the S0 mode Lamb wave and the buried micro-cracks of various dimensions are simulated by using the finite element method. Fourier frequency spectrum analysis is applied to the received time domain signal and fundamental frequency amplitudes, and sum and difference frequencies are extracted and simulated. Simulation results indicate that nonlinear Lamb waves have different sensitivities to various crack sizes. There is a positive correlation among crack length, height, and sum and difference frequency amplitudes for an aluminum plate, with both amplitudes decreasing as crack thickness increased, i.e., nonlinear effect weakens as the micro-crack becomes thicker. The amplitudes of sum and difference frequency are positively correlated with the length and width of the zero-thickness cohesive element in the composite laminates. Furthermore, amplitude ratio change is investigated and it can be used as an effective tool to detect inner defects in thin 3D plates.
Thin plate structures are widely used in engineering fields, such as shipbuilding, railway vehicles, and aerospace. However, barely visible fatigue damage and cracks are often caused by a variety of processing factors, including external impact, chemical corrosion, thermal fatigue, etc. Therefore, the detection of early micro-cracks is essential to avoid engineering factor and structure failures with consequential potentially disastrous accidents. Nondestructive testing (NDT)[1] techniques have been previously verified to meet the requirements for real-time and reliability, and, combined with recently developed measurement and calculation methods, they become irreplaceable techniques for structural health monitoring (SHM)[2] applications. The SHM systems can monitor structural changes instantly, and provide damage diagnosis to effectively judge the structure health and outline a reasonable maintenance plan.[3] Ultrasonic Lamb wave techniques have been extensively used for thin plate NDT, since they can transfer energy long distance and detect internal defects by interrogating the whole thickness of the structure.[4,5]
Conventional ultrasonic Lamb wave techniques are universally based on linear theory and usually dependent on measuring several specific parameters, including acoustic velocity, and transmission and reflection coefficients, to confirm material elastic properties or evaluate the damage. However, the measured data are sensitive to open cracks, macroscopic damage, or through-holes, thus causing significant transmission barriers, whereas they are much less sensitive to evenly distributed micro-cracks or material degradation prior to forming visible damage.[6,7] Consequently, ultrasonic NDT methods based on linear theory are not suitable for detecting the buried micro-cracks.
Nonlinear ultrasonic techniques can beak through accuracy and sensitivity limitations.[8,9] The main distinction between linear and nonlinear ultrasound technique lies in the fact that the defect features for the latter are often associated with another acoustic signal whose frequency differs from the excitation signals. Ultrasonic wave nonlinearity encompasses nonlinear phenomena such as wave distortion, harmonic generation, and sideband formation when the ultrasonic wave propagates in materials. At present, nonlinear ultrasonic techniques have been widely studied in the areas of nonlinear ultrasonic resonance spectroscopy,[10] high order harmonics,[11] and subharmonic and mixing responses.[12] Nonlinear ultrasonic technique applications have been investigated as effective methods to overcome linear technique deficiencies.[13,14]
Nonlinear Lamb wave detection techniques have received increasingly attention due to their long propagation distance and high detection efficiency in thin plate structures.[15,16] Many general researches and simulation studies are based on nonlinear Lamb wave testing for non-destructive evaluation (NDE). Several studies have considered defect instances and nonlinear attribute influences for single material plate and composite laminates, most of which focus on higher harmonics (mainly second harmonic) generated from micro-cracks. Wang et al.[17] investigated fatigue damage identification in carbon fibre reinforced steel plates; Zhao et al.[18] analyzed nonlinear Lamb wave generation mechanism with random micro-crack distributions. Sotoudeh et al.[19] installed specific sensors to obtain the nonlinear Lamb wave response signals experimentally, acquiring delamination damage approximate dimension and location by using the damage imaging method. Yang et al.[20] investigated the crack opening and the influence of incident wave angle on Lamb wave second harmonic generation. Li et al.[21] used nonlinear Lamb wave to detect material degradation during thermal cycling. Most of nonlinear Lamb wave studies considered single-frequency excitation. However, the harmonic generation is practically difficult due to its non-determinacy, i.e., it is hard to judge whether the measured nonlinearity is caused by defect or experimental devices.[22]
Nonlinear Lamb wave mixing is an effective method to break through these recognized limitations, based on the influence of material nonlinear attributes between the two intersecting ultrasound waves.[22] Nonlinear Lamb wave mixing relies on the interaction characteristics between two incident waves of different frequencies in the structure, thus achieving the considerable detection of inner defect. If the structure is successive, no new frequency components will be generated when the two waves meet. On the contrary, if the structure is non-successive, interactions will occur in associated regions when the two waves meet in the nonlinear region, resulting in the coupling the two waves. New frequency components will be generated in the frequency domain, including sum and difference frequencies. The wave mixing technique has unique advantages compared with the second-harmonics-generating traditional nonlinear ultrasonic techniques. Different detection regions can be scanned over by adjusting the excitation location of wave mixing.[23] Second, wave modes, frequencies, and propagation directions have great and relatively flexible selectivity to avoid redundant harmonics caused by some experimental device in a testing system.[24] Nonlinear Lamb wave mixing detection hasreceived increasingly attention due to its great potential to detect micro-cracks and damage, which has gradually been used in NDT. Lee et al.[25] studied the feasibility of Lamb wave mixing nonlinear technique for detecting the defects in thin plates.
The main purpose of this paper is to investigate damage detection effects for nonlinear Lamb waves by using mixing excitation in propagation through three-dimensional (3D) thin plate (aluminum plate and composite laminates) structures. We first introduce the basic nonlinear Lamb wave frequency mixing theory, and then establish a 3D finite element model based on mixing excitation by using ABAQUS software[23] to generate Lamb wave S mode signal. Nonlinear relationships between S mode signals and different dimensional cracks are discussed. Amplitude ratio variation is also analyzed and clearly demonstrates the nonlinear correlation between Lamb wave and crack dimensions in an intuitive manner.
Ultrasonic Lamb waves are stress waves generated by acoustic guided waves propagating in a homogeneous and isotropic thin plate structure, where the plate thicknesshas the same order of magnitude as the excitation signal wavelength.[22] Lamb waves are formed in thin plates by successive reflections, transmissions, and mode transformations due to interactions with structural boundaries. According to whether particle vibrations are symmetrical with respect to the center plane of the plate, Lamb waves can be divided into symmetric and anti-symmetric modes.[26,27] Symmetric modes include S0, S1, S2, …, Sn, and anti-symmetric modes include A0, A1, A2, …, An. Dispersive and multimodal Lamb wave characteristics can be described by the Raleigh–Lamb relationship[28]
where k is the wave number in the direction of propagation; h is the plate thickness; exponent ±1 expresses symmetric and anti-symmetric mode, respectively; w is the angular frequency;[29]
with cl and ct denoting the longitudinal and transverse wave velocity inside the plate, respectively.
As shown in Eq. (
Wave interaction propagating in multiple layered composites generally depends on the frequency, geometry, constituent properties, and propagation direction. Theoretical curves for composite laminates can be calculated from the Vallen Dispersion program, version R2017.0504.2, from Vallen–Systeme GmbH.[30]
Consequently, appropriate lower frequencies should be chosen to display only two fundamental modes (S0 and A0), thus making them analyzed conveniently and simply. We select the original symmetric mode (S0 mode) as the desirable method for nonlinear Lame wave mixing excitation used in NDT. The reason is that the S0 mode is virtually nondispersive, significantly reducing signal complexity; stress is relatively uniform through the plate thickness, hence micro-crack sensitivity is not reliant on the thickness of damaged region; and this is the fastest mode, ensuring that it will be the first wave packet to reach the receiving destination, hence simply distinguishing superfluous signals.[22,31] Thus, an appropriate excitation manner should be selected to produce the single S0 mode.
Nonlinear mixing effect is associated with material nonlinear elastic behavior, i.e., the relationship between stress, σ, and strain, ε, is nonlinear, which can be described by the nonlinear Hooke law[32]
where E0 is the Young’s modulus and β is the second order nonlinear elastic coefficient, called the acoustic nonlinearity parameter in this paper.
Due to the existence of nonlinear sources, such as crack damage in the structure, system input and output can be simplified into
where u(t) represents the incident signal; f (t) is the system response; α and β are constants representing the first- and second-order nonlinear coefficients, respectively; and h(t) is an undefined function to represent noise, which is ignored in the following discussion.
Suppose that an incoming signal consists of two sinusoidal signals with different frequencies,
where x is the displacement; A1, A2 and f1, f2 represent the two sinusoidal signal amplitudes and frequencies, respectively; and k1 and k2 are the signal wave numbers.[22] Then, regardless of the reflection of the S0 mode signal, the corresponding solution can be expressed as
and we can make Eq. (
which describes nonlinear system effect for mixed-frequency excitation.
Thus, interaction between the two sinusoidal signal components appears due to nonlinear stress-strain relationship, thus generating two new frequency components: sum frequency and difference frequency.[22]
The acoustic nonlinear coefficient, β, can be simplified into
where A1 and A2 represent the fundamental frequency signal amplitudes, respectively.[12,22,33]
In this paper we analyze the time domain signals received from 3D simulation model in the frequency domain using fast Fourier transform (FFT). A1 and A2 can be relatively easily measured and calculated, and β is also called the amplitude ratio, which can be used as a damage evaluation parameter for buried micro-cracks in thin plates.
We established 3D numerical simulations and performed explicit dynamic analyses by using ABAQUS Dynamic/Explicit. The software was used to simulate nonlinear Lamb waves propagating in both aluminum plate and composite laminates.
Table
In the aluminum plate model, the buried micro-crack was located 600 mm away from the left side surface in the x direction, and was modeled as an elliptical cylinder (Fig.
A suitable mesh division method was devised to ensure computational accuracy and model efficiency. Although smaller mesh elements can improve computational accuracy, this also requires more calculation times and computer resources. Therefore, appropriate mesh density and computational time step should be selected for the model to ensure that the system simulation requirements are satisfied.
For 100-kHz and 350-kHz mixed signals in the aluminum plate model, following Eqs. (
In this study, we also simulated 3D thin composite laminates, where composite laminate model size was the same as that for the aluminum plate. Table
Model size, damage region, and other parameters were generally consistent with those for the aluminum plate model (Fig.
Since each individual composite laminate layer was composed of the same fiber reinforced material, a local coordinate system was created to exhibit lamina material properties.[35] Ten ply layers were used to generate a quasi-isotropic layup sequence [45/− 45/0/90/45]s,[36] where figure
After establishing the 3D aluminum plate model, we conduct a comparative initial time domain response analysis for undamaged and damaged plate with a buried micro-crack 20 mm×1.6 mm×0.0001 mm (length (l) × height (h) × thickness (d)) as shown in Fig.
Figures
In Fig.
More comprehensive analyses can be studied in the frequency domain. Figure
Figure
Figure
Signal amplitudes in the frequency domain for damaged plate are significantly larger than for undamaged plate (Fig.
To investigate the relationship between nonlinear effects and buried micro-crack or delamination damage dimension, several simulations are performed for the 3D aluminum plate with various micro-crack sizes. Group 1 is for simulating the buried micro-cracks with fixed height and thickness (h = 1.6 mm, d = 0.0001 mm) and various lengths (l = 5, 9, 11, 16, 18, 20, and 25 mm). Group 2 is for simulating the buried micro-cracks of fixed length and thickness (l = 20 mm and d = 0.0001 mm) and various heights (h = 0.5, 0.6, 0.7, 0.9, 1.2, 1.4, and 1.6 mm). Finally, group 3 is for simulating the buried micro-cracks with fixed length and height (l = 20 mm and h = 1.6 mm) and various thicknesses (d = 0.0001, 0.0005, 0.0008, 0.002, 0.003, 0.004, and 0.006 mm). The corresponding simulation results are shown in Fig.
Two simulation groups are also investigated for different delamination damage dimensions in 3D composite laminates. In group 4 considered are the zero thickness cohesive elements with constant width (w = 20 mm) and various lengths (l = 1.2, 1.3, 1.5, 1.6, 1.7, and 2 mm). In group 5 considered are the zero thickness cohesive elements with constant length (l = 2 mm) and various widths (w = 8, 10, 13, 15, 17, and 20 mm). Figure
Figure
We investigate the change rule for nonlinear signals. From the observed signal amplitudes, we analyzed β, (Eq. (
where A3 and A4 represent the sum and difference frequency signal amplitudes, respectively, β1 expresses the amplitude ratio for the sum frequency component, and β2 for the difference frequency component. Figure
Figure
Thus, amplitude ratios strongly depend on micro-crack dimensions, i.e., acoustic nonlinearity decreases as the 3D buried micro-crack thickens. Consequently, the nonlinear Lamb wave S0 mode exhibits greater sensitivity to buried micro-crack thickness in thin 3D aluminum plate.
Amplitude ratio variations for composite laminates exhibit different trends (Fig.
The proposed method relies only on the Fourier spectrum amplitude ratio rather than any other baseline data. Thus, the amplitude ratio acts as indicator to identify incipient buried micro-crack or delamination damage. This has potential applications in internal defect detection in thin plates through using nonlinear Lamb waves.
We construct 3D finite element numerical model for thin aluminum plate with buried micro-cracks and that for composite laminates with inner delamination damage to investigate Lamb wave nonlinear phenomena for mixed-frequency excitation. Some conclusions are drawn as follows.
(i) Time domain simulations of undamaged and damaged plates show that new wave packets appear due to the interaction between the nonlinear Lamb wave and micro-crack or delamination damage. Thus, the new wave packets are the main research objects.
(ii) Frequency domain analyses of wave-packet FFT for undamaged and damaged plate aluminum plate and composite laminate are performed. The FFT is mainly applied to the new wave packets in the damaged plates. Simulation results confirm the existence of sum and difference frequencies components. The sum and difference frequency amplitude variations are analyzed respectively by changing micro-crack length (l), height (h), thickness (d), delamination damage length (l), and width (w). Different sizes exhibit different nonlinear behaviors, confirming that the sum and difference frequencies provide a sensitive tool for defect detection.
(iii) The sum and difference frequency amplitude ratio variations are investigated and shown to be strongly dependent on micro-crack or delamination damage dimensions. Combined with the nonlinear Lamb wave variation sensitivity to different defects size parameters, the unique amplitude ratio can provide an important index for defect detection.
Thus, the simulation results of aluminum plate and composite laminate provide a feasible method to identify and evaluate the incipient crack defects in thin 3D plate structures with mixed nonlinear Lamb waves. Also, the research in this paper will provide theoretical guidance for future laboratory research.
[1] | |
[2] | |
[3] | |
[4] | |
[5] | |
[6] | |
[7] | |
[8] | |
[9] | |
[10] | |
[11] | |
[12] | |
[13] | |
[14] | |
[15] | |
[16] | |
[17] | |
[18] | |
[19] | |
[20] | |
[21] | |
[22] | |
[23] | |
[24] | |
[25] | |
[26] | |
[27] | |
[28] | |
[29] | |
[30] | |
[31] | |
[32] | |
[33] | |
[34] | |
[35] | |
[36] | |
[37] | |
[38] | |
[39] |