Applying life estimation approaches to determine in-service life of structures and plan the inspection schedules accordingly are becoming acceptable safety design procedures in aerospace. However, these design systems shall be fed with reliable parameters related to material properties, loading conditions and defect characteristics. In this context, the role of non-destructive (NDT) testing reliability is of high importance in detecting and sizing defects. Eddy current test (ECT) is an electromagnetic NDT method frequently used to inspect tiny surface fatigue cracks in sensitive industries. Owing to the new advances in robotic technologies, there is a trend to integrate the ECT into automated systems to perform NDT inspections more efficiently. In fact, ECT can be effectively automated as to increase the coverage, repeatability and scanning speed. The reliability of ECT scanning, however, should be thoroughly investigated and compared to conventional modes of applications to obtain a better understanding of the advantages and shortcomings related to this technique. In this contribution, a series of manual and automated ECT tests are carried out on a set of samples using a split-D reflection differential surface probe. The study investigates the level of noise recorded in each technique and discuss its dependency on different parameters, such as surface roughness and frequency. Afterwards, a description of the effect of crack orientation on ECT signal amplitude is provided through experimental tests and finite element simulations. Finally, the reliability of each ECT technique is investigated by means of probability of detection (POD) curves. POD parameters are then extracted and compared to examine the effect of scanning index, frequency and automation on detection reliability.

This paper presents the results of a project aimed at evaluating the performance of ultrasonic techniques for detecting flaws in Francis turbine runners. This work is the first phase of a more ambitious program aimed at improving the reliability of inspection of critical areas in turbine runners. Francis runners may be utilized to supply power during peak periods, which means that they experience additional load stress associated with start and stop sequences. Inspection during manufacturing is then of paramount importance to remove as much as feasible all flaw initiation sites before the heat treatment. This phase one objective is to collect initial data on a simplified mock-up and then to compare the experimental ultrasonic data with the results of simulations performed by CIVA, a computer simulation package. The area of interest is the region with the highest stress between the blade and the web. A welded T-joint coupon made of UNS S41500 was manufactured to represent this high-stress area. During the FCAW welding process, ceramic beads were embedded in the weld to create discontinuities whose size is in the critical range to initiate a crack. Inspection of the material was carried out by various nondestructive testing (NDT) methods namely conventional pulse-echo, phased array, total focusing method (TFM). With these results, detection rates were obtained in order to compare the effectiveness of each method.

Structural health monitoring is a prominent alternative to the scheduled maintenance of safety-critical components. The nondispersive nature as well as the through-thickness mode shape of the fundamental shear horizontal guided wave mode (SH ${}_0$ ) make it a particularly attractive candidate for ultrasonic guided wave structural health monitoring. However, plane wave excitation of SH ${}_0$ at a high level of purity remains challenging because of the existence of the fundamental Lamb modes (A ${}_0$ and S ${}_0$ ) below the cutoff frequency thickness product of high-order modes. This paper presents a piezoelectric transducer concept optimized for plane SH ${}_0$ wave transduction based on the transducer geometry. The transducer parameter exploration was initially performed using a simple analytical model. A 3D multiphysics finite element model was then used to refine the transducer design. Finally, an experimental validation was conducted with a 3D laser Doppler vibrometer system. The analytical model, the finite element model, and the experimental measurement showed excellent agreement. The modal selectivity of SH ${}_0$ within a 20 ${}^{\circ }$ beam opening angle at the design frequency of 425 kHz in a 1.59 mm aluminum plate was 23 dB, and the angle of the 6 dB wavefront was 86 ${}^{\circ }$ .