The capability of embedded piezoelectric wafer active sensors (PWAS) to excite and detect tuned Lamb waves for structural health monitoring is explored. First, a brief review of Lamb waves theory is presented. Second, the PWAS operating principles and their structural coupling through a thin adhesive layer are analyzed. Then, a model of the Lamb waves tuning mechanism with PWAS transducers is described. The model uses the space domain Fourier transform. The analysis is performed in the wavenumber space. The inverse Fourier transform is used to return into the physical space. The integrals are evaluated with the residues theorem. A general solution is obtained for a generic expression of the interface shear stress distribution. The general solution is reduced to a closed-form expression for the case of ideal bonding which admits a closed-form Fourier transform of the interfacial shear stress. It is shown that the strain wave response varies like sin a, whereas the displacement response varies like sinc a. Maximum coupling is achieved when the PWAS length equals the half wavelength of a particular Lamb wave mode. Since Lamb wave modes wavelengths vary with frequency, the tuning of certain modes at certain frequencies can thus be achieved. Tuning curves are derived and verified against experimental results. A particular S₀ mode ‘sweet spot’ is found at 300 kHz for a 7-mm PWAS attached to a 1.6-mm aluminum plate. Crack detection via the pulse echo technique using the phased array principle and tuned S₀ mode Lamb waves is demonstrated as an effective structural health monitoring method.

Piezoelectric wafer active sensors may be applied on aging aircraft structures to monitor the onset and progress of structural damage such as fatigue cracks and corrosion. The state of the art in piezoelectric-wafer active sensors structural health monitoring and damage detection is reviewed. Methods based on (a) elastic wave propagation and (b) the Electro-Mechanical (E/M) impedance technique are cited and briefly discussed. For health monitoring of aging aircraft structures, two main detection strategies are considered: the E/M impedance method for near field damage detection, and wave propagation methods for far-field damage detection. These methods are developed and verified on simple-geometry specimens and on realistic aging aircraft panels with seeded cracks and corrosion. The experimental methods, signal processing, and damage detection algorithms are tuned to the specific method used for structural interrogation. In the E/M impedance method approach, the high-frequency spectrum, representative of the structural resonances, is recorded. Then, overall-statistics damage metrics can be used to compare the impedance signatures and correlate the change in these signatures with the damage progression and intensity. In our experiments, the (1 R²)³ damage metric was found to best fit the results in the 300-450 kHz band. In the wave propagation approach, the pulse-echo and acousto-ultrasonic methods can be utilized to identify the additional reflections generated from crack damage and the changes in transmission phase and velocity associated with corrosion damage. The paper ends with a conceptual design of a structural health monitoring system and suggestions for aging aircraft installation utilizing active-sensor arrays, data concentrators, wireless transmission, and a health monitoring and processing unit.

The benefits and limitations of using embedded piezoelectric active sensors for structural identification at ultrasonic frequency are highlighted. An analytical model based on structural vibration theory and theory of piezoelectricity was developed and used to predict the electro-mechanical (E/M) impedance response, as it would be measured at the piezoelectric active sensor’s terminals. The model considers one-dimension structures and accounts for both axial and flexural vibrations. Experiments were conducted on simple specimens in support of the theoretical investigation, and on realistic turbine blade specimen to illustrate the method’s potential. It was shown that E/M impedance spectrum recorded by the piezoelectric active sensor accurately represents the mechanical response of a structure. It was further proved that the response of the structure is not modified by the presence of the sensor, thus validating the latter’s noninvasive characteristics. It is shown that such sensors, of negligible mass, can be permanently applied to the structure creating a nonintrusive sensor array adequate for on-line automatic structural identification and health monitoring. The sensor calibration procedure is outlined. Numerical estimation of the noninvasive properties of the proposed active sensors in comparison with conventional sensors is presented. Self-diagnostics capabilities of the proposed sensors were also investigated and methods for automatic self-test implementation are discussed. The paper underlines that the use of piezoelectric wafer active sensors is not only advantageous, but, in certain situations, may be the sole investigative option, as in the case of precision machinery, small but critical turbine-engine parts, and computer industry components.

The use of the electro-mechanical (E/M) impedance method for health monitoring of thin plates and aerospace structures is described. As a nondestructive evaluation technology, the E/M impedance method allows us to identify the local dynamics of the structure directly through the E/M impedance signatures of piezoelectric wafer active sensors (PWAS) permanently mounted to the structure. An analytical model for 2-D thin-wall structures, which predicts the E/M impedance response at PWAS terminals, was developed and validated. The model accounts for axial and flexural vibrations of the structure and considers both the structural dynamics and the sensor dynamics. Calibration experiments performed on circular thin plates with centrally attached PWAS showed that the presence of damage modifies the high-frequency E/M impedance spectrum causing frequency shifts, peak splitting, and appearance of new harmonics. Overall-statistics damage metrics and probabilistic neural network (PNN) are used to classify the spectral data and identify damage severity. On thin-wall aircraft panels, the presence of damage influences the sensors E/M impedance spectrum. When crack damage is in the PWAS medium field, changes in the distribution of harmonics take place and when crack damage is in the PWAS near field, changes in both the harmonics and the dereverberated response are observed. These effects are successfully classified with PNN and overall-statistics metrics, respectively. This proves that permanently attached PWAS in conjunction with the E/M impedance method can be successfully used in structural health monitoring to detect the presence of incipient damage through the examination and classification of the high-frequency E/M impedance spectra.

Embedded-ultrasonics structural radar (EUSR) is a new concept and methodology for in situ nondestructive evaluation (NDE) and structural health monitoring (SHM) of thin-wall structures. EUSR consists of: (a) an array of piezoelectric wafer active sensors (PWAS) embedded into the structure; and (b) electronic modules for signal transmission/reception, processing, and interpretation. EUSR utilizes guided elastic waves (Lamb waves) generated omnidirectionally into the thin-wall structure by surface-mounted permanently attached PWAS. The paper starts with the general concepts of the EUSR algorithm: transmission beamforming, reception beamforming, and time-of-fight (TOF) determination. Next, details of the Lamb wave generation with PWAS, verification of group-velocity dispersion curves, identification of optimal excitation frequency, and confirmation of wave front omnidirectionality are discussed. In the third part of the paper, the actual implementation of the EUSR method in a proof-of-concept demonstration is presented. The construction of the PWAS-phased array is described, and detection of cracks located broadside and offside of the PWAS array is illustrated. The method is shown to be easy to use through a visually interactive LabView™ interface. Very good detection accuracy is observed. The proof-of-concept experiments presented in this paper were illustrated on metallic structures; however, the EUSR concept may also work on composite and hybrid structures, although the range of detection may be reduced by the medium attenuation.

In the beginning, the classical one-dimensional analysis of piezoelectric active sensors is reviewed. The complete derivation for a free-free sensor is then extended to cover the cases of clamped and elastically constrained sensors. An analytical model based on structural vibration theory and theory of piezoelectricity was developed and used to predict the electromechanical (E/M) impedance response, as it would be measured at the piezoelectric active sensor’s terminals. The model considers one-dimensional structures and accounts for both axial and flexural vibrations. The numerical analysis was performed and supported by experimental results. Experiments were conducted on simple beam specimens to support the theoretical investigation, and on thin gauge aluminum plates to illustrate the method’s potential. It was shown that E/M impedance spectrum recorded by the piezoelectric active sensor accurately represents the mechanical response of a structure. It was further proved that the response of the structure is not modified by the presence of the sensor, thus validating the sensor’s non-invasive characteristics. The sensor calibration procedure is outlined and statistical analysis was presented. It was found that PZT active sensors have stable and repeatable characteristics not only in as-received condition, but also while mounted on 1-D or 2-D host structure. It is shown that such sensors, of negligible mass, can be permanently applied to the structure creating a non-intrusive sensor array adequate for on-line automatic structural identification and health monitoring.