We explore a conformal gradient-index phononic crystal lens integrated within a pipe to amplify guided wave modes toward improved ultrasonic inspection of pipelines. The proposed conformal lens is composed of an array of cylindrical steel stubs attached to the outer surface of a steel pipe, which are tailored according to the hyperbolic secant profile of refractive index in the circumferential direction of the pipe. Hence, the ultrasonic guided wave energy is focused in the axial direction of the pipe and amplified at the focal point of the lens. Refractive indices are calculated using dispersion curves obtained from the finite element simulations of the stubbed unit cells, and the curved lens is designed for the second longitudinal wave mode of the pipe, which is commonly used in guided wave testing. The proposed lens design is implemented on a steel pipe, which is typically used in the distribution networks utilized in cities, and simultaneous focusing of longitudinal wave modes in a broad frequency range is verified through both numerical models and experimental measurements.

Welding defects such as lack of penetration, undercutting, crater crack, burn-through and porosity can occur during manufacturing. Assessing weld quality using nondestructive evaluation methods is important for the quality assurance of welded parts. In this paper, the measurement of weld penetration, which is directly related to weld integrity, is investigated by means of ultrasonics. Both linear and nonlinear ultrasonic methods are studied to assess their sensitivities to weld penetration. Welded plates with different penetration depths controlled by changing weld heat input are manufactured using gas metal arc welding (GMAW). Microscopic properties are assessed after the ultrasonic measurements are completed. Numerical models are built using the weld profile obtained from macrographs to explain the relationship between linear ultrasonic and weld penetration. A quantitative correlation between weld morphology (shape, width and depth) and the energy of linear ultrasonic signal is determined, where the increase of weld bead penetration exceeding the plate thickness results in decrease of the energy of the ultrasonic signal. Minimum detectable weld morphology using linear ultrasonics is defined depending on the selected frequency. Microhardness measurement is conducted to explain the sensitivity of nonlinear ultrasonics to both weld penetration and heterogeneity in weld. The numerical and experimental results show that the weld geometry influences the ultrasonic measurement other than the materials’ properties.

We present torsional wave focusing in cylindrical structures integrated with conformal gradient-index phononic crystal (GRIN-PC) lenses. The mechanical lens modifies the refractive characteristics of propagating waves along the axial direction such that the torsional wave energy focuses at a desired point with an increased amplitude. In this paper, our main goal is to exploit the GRIN-PC concept for amplification of the fundamental torsional wave mode, namely, T(0,1), which is especially favorable in the guided wave ultrasonic testing of pipelines and can extend important structural information over long-range pipelines. To this end, we first study d35 piezoelectric transducer arrays through multiphysics simulations coupling piezoelectric and solid mechanics models and determine the optimal number of transducers to achieve the excitation of torsional plane wave. Two-dimensional Fourier transform as well as the tangential displacement histories around the pipe circumference at various axial positions verify the pure T(0,1) excitation, which is validated with experiments. Next, we design, fabricate, and numerically and experimentally study the conformal GRIN-PC for T(0,1) mode focusing in a range of ultrasonic frequencies, from 30 to 50 kHz. Measurements show that the amplitude of the torsional wave mode is amplified by 39% at the focal point with the presence of the GRIN-PC lens.

Phononic crystals have the ability to manipulate the propagation of elastic waves in solids by generating unique dispersion characteristics. They can modify the conventional behavior of wave spreading in isotropic materials, known as attenuation, which negatively influences the ability of acoustic emission method to detect active defects in long-range, pipe-like structures. In this study, pipe geometry is reconfigured by adding gradient-index (GRIN) phononic crystal lens to improve the propagation distance of waves released by active defects such as crack growth and leak. The sensing element is designed to form a ring around the pipe circumference to capture the plane wave with the improved amplitude. The GRIN lens is designed by a special gradient-index profile with varying height stubs adhesively bonded to the pipe surface. The performance of GRIN lens for improving the amplitude of localized sources is demonstrated with finite element numerical model using multiphysics software. Experiments are conducted using pencil lead break simulating crack growth, as well as an orifice with pressured pipe simulating leak. The amplitude of the burst-type signal approximately doubles on average, validating the numerical findings. Hence, the axial distance between sensors can be increased proportionally in the passive sensing of defects in pipe-like geometries.

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