A THEORETICAL MODEL FOR THE ULTRASONIC DETECTION OF SURFACE-BREAKING CRACKS WITH THE SCANNING LASER SOURCE TECHNIQUE Irene Arias and Jan D. Achenbach Center for Quality Engineering and Failure Prevention. Northwestern University, Evanston, IL 60208 ABSTRACT. In work reported at last year's QNDE meeting, a first step towards the development of a model for the Scanning Laser Source (SLS) technique was presented, which provides an analytical formulation for the transient response of an isotropic, homogeneous, linearly elastic half-space submitted to a pulsed laser line source operating in the therrnoelastic regime. The formulation takes into account optical penetration into the material and thermal diffusion from, the source, and is therefore a suitable representation not only for the far field, but also for the field near the laser source, where these effects become significant. In the present paper, we report the progress made in the numerical analysis by the Boundary Element Method of the interactions of the previously obtained laser generated field with surface-breaking cracks. Some preliminary simulations of SLS experimental observations are presented. INTRODUCTION Surface-breaking cracks in a structure can be ultrasonically detected using Lamb and Rayleigh waves. Conventional ultrasonic flaw detection methodologies require the generation of an ultrasonic wrave packet that travels through a structure and interacts with existing flaws within the structure. Either reflected echoes or transmitted signals may be monitored in the pulse-echo or pitch-catch modes of operation. In order to generate the wa,ve packets for conventional pulse-echo and pitch-catch techniques, high-power pulsed lasers have emerged as versatile therrnoelastic sources of ultrasound. Indeed, laser based ultrasonic (LBU) techniques provide a number of advantages over conventional ultrasonic methods such a..s higher spatial resolution, noncontact generation and detection of ultrasonic waves, use of fiber optics and ability to operate on curved or rough surfaces [6]. In both the pitch-catch and pulse-echo methods, the source is expected to generate a well established ultrasonic wave, which then interacts with existing flaws. The limitations on the size of the flaws that can be detected using these methods are determined by the ultrasonic reflectivity or transmittance of the flaw for the particular wavelength used, and by the sensitivity of the ultrasonic detector. As might be expected, small flaws give rise to weak reflections or small changes in the amplitude of transmitted signals, often too weak to be detected with existing laser detectors. CP657, Review of Quantitative Nondestructive Evaluation Vol. 22, ed. by D. O. Thompson and D. E. Chimenti © 2003 American Institute of Physics 0-7354-0117-9/03/S20.00 281 II I RECEIVER III Surface-breaking crack FIGURE 1. FIGURE 1. Configuration Configuration for for the the SLS SLS technique. technique. Interferometer signal [mV] 4.0 4.0 -3 II I I 3'° 3.0 III 2.0 2.0 1.0 0 f^W^^ -1.0 -1.0 -2.0 -2.0 0 0.5 0.5 1.0 1.0 1.5 1.5 2.0 2.0 2.5 2.5 3.0 3.0 0 0.5 0.5 1.0 1.0 1.5 1.5 2.0 2.0 2.5 2.5 3.0 3.0 0 0.5 0.5 1.0 1.0 1.5 1.5 2.0 2.0 2.5 2.5 3.0 3.0 Ps] Time Time [[//s] FIGURE 2. FIGURE 2. Characteristic Characteristic time time signal signal recorded recorded at at receiver receiver for for three three different different positions positions of of the the laser laser c The source relative relative to to the the crack. crack. Copyright 2000 source Copyright 2000 © The American American Society Society for for Nondestructive Nondestructive Testing, Testing, Inc. Inc. Reprinted from from [5] Reprinted [5] with with permission permission from from Materials Materials Evaluation. Evaluation. In this Ill this paper paper we we provide provide the the theoretical theoretical background background for for an an alternate alternate approach approach for for ultrasonic detection of small surface-breaking cracks using laser-generated ultrasonic detection of small surface-breaking cracks using laser-generated ultrasound ultrasound -– the the Scanning Scanning Laser Laser Source Source (SLS) (SLS) technique technique [5]. [5]. THE SCANNING SCANNING LASER LASER SOURCE SOURCE TECHNIQUE TECHNIQUE The The Scanning Scanning Laser Laser Source Source (SLS) (SLS) technique technique has has been been proposed proposed by by Kromine Kromine et et al. [5] as a method to detect surface breaking discontinuities by monitoring the al [5] as a method to detect surface breaking discontinuities by monitoring the changes changes in the the laser laser generated generated ultrasonic ultrasonic signal signal as the laser laser source source passes passes over over the the discontinuity. discontinuity. in as the This method differs from conventional techniques in that it is the direct This method differs from conventional techniques in that it is the direct generated generated ultrasonic signal that is ultrasonic signal that is detected, detected, rather rather than than the the reflections reflections of of the the generated generated waves waves by by the defect. the defect. The proposed proposed technique technique employs The employs aa line line focused focused high high power power laser laser source source which which is swept across the test specimen and passes over surface-breaking anomalies. is swept across the test specimen and passes over surface-breaking anomalies. The The generated ultrasonic waves are generated ultrasonic waves are detected detected with with an an ultrasonic ultrasonic detector detector located located either either at at aa fixed distance from the laser source or at a fixed position on the test specimen. This fixed distance from the laser source or at a fixed position on the test specimen. This technique can can be technique be used used to to detect detect discontinuities discontinuities with with arbitrary arbitrary orientations. orientations. Kromine et experimentally verified Kromine et al. al. have have experimentally verified the the SLS SLS approach approach by by testing testing an an aluminum with aa surface aluminum specimen specimen with surface breaking breaking fatigue fatigue crack. crack. A A schematic schematic of of the the inspection inspection technique is technique is shown shown in in Fig. Fig. 1, 1, where where three three representative representative positions positions of of the the source source relative relative to the the crack crack have have been been plotted. plotted. The The variation variation of to of the the amplitude amplitude and and frequency frequency of of the the measured ultrasonic measured ultrasonic signals signals was was studied studied as as the the laser laser source source approaches, approaches, passes passes over over and and moves behind behind the the discontinuity discontinuity (positions moves (positions (I), (I), (II), (II), and and (III) (III) in in Fig. Fig. 11 respectively). respectively). A characteristic signature of the crack was found as both a specific A characteristic signature of the crack was found as both a specific variation variation of of the the ultrasonic amplitude and a frequency shift of the generated signals (see Fig. 3). ultrasonic amplitude and a frequency shift of the generated signals (see Fig. 3). The The following aspect signature in the ultrasonic ultrasonic amplitude amplitude should should be be noted. noted. following aspect of of the the signature in the 282 5 II 5.0 4.0 I Crack Spectrum maximum, MHz Ultrasonic amplitude [mV] 6.0 6.0 I 3.0 III 2.0 1.0 II III 4 3 2 Position Position of of the the crack crac 1 0 0 1.0 1.0 2.0 2.0 3.0 3.0 4.0 4.0 5.0 6.0 0 0 SLS SLS position position [mm] [mm] 1 2 3 4 5 6 SLS SLS position, position, mm mm FIGURE FIGURE 3. 3. Experimental Experimental signatures signatures of ofthe the defect defect in in the the ultrasonic ultrasonic amplitude amplitude (left) (left) and and the the maximaximum mum frequency frequency (right) (right) of of the the generated generated signal signal as as the the laser laser source source scans scans over over aa surface-breaking surface-breaking crack. crack. c The Copyright Copyright 2000 2000 © The American American Society Society for for Nondestructive Nondestructive Testing, Testing, Inc. Inc. Reprinted Reprinted from from [5] [5] with with permission permission from from Materials Materials Evaluation. Evaluation. (I) (I) When When the the source source is is far far ahead ahead of of the the defect, the amplitude of the generated direct signal signal isis constant constant and and unaffected unaffected by by the the presence presence of of the the defect defect (see (see zone (I) (I) in Fig. 3). 3). The The signal signal isis of ofsufficient sufficient amplitude amplitude above above the the noise noise floor floor to to be unambiguously unambiguously picked picked up up by by the the laser laser detector. detector. A A weak reflection reflection from the crack is barely visible amidst amidst the the noise noise (see (see Fig. Fig. 2(I)). 2(1)). (II) (II) As As the the source source approaches approaches the the defect, defect, the the amplitude of of the detected signal significantly icantly increases. increases. This This increase increase (from (from aa level level that that was was already already sufficiently sufficiently above above the the noise noise floor) floor) isis more more readily readily detectable detectable with with aa laser laser interferometer interferometer than any any weak weak echoes echoes from from the the crack (see (see Fig. 2(II)). 2(11)). The increase in signal amplitude is attributed attributed to to two two mechanisms: mechanisms: (a) (a) interactions interactions of of the the direct direct ultrasonic ultrasonic wave with the the reflections reflections from from the the crack, crack, and and (b) (b) changes in in the conditions of laser generation ation of of ultrasound ultrasound when when the the laser laser source source isis in in the the vicinity vicinity of of the the crack. crack. The The changes changes in in generation generation constraints constraints play play also also aa role role in in the the subsequent subsequent drop in the signal signal amplitude amplitude as as the the SLS SLS passes passes over over the the defect. (III) (Ill) As As the the source source moves moves behind behind the the defect, the amplitude remains constant and lower than than in in zone zone (I) (I) due due to to the the scattering of of the generated signal by the crack (see Fig. Fig. 2(III) 2(111) and arid zone zone (III) (III) on on Fig. Fig. 3). 3). The The modeling modeling of of the the SLS SLS technique technique requires requires an an appropriate appropriate description description of of the the two main mechanisms involved in both the amplitude and the spectral variations two main mechanisms involved in both the amplitude and the spectral variations in in order order to to develop develop aa simulation simulation tool tool that that combined combined with with the experimental method can form form the the basis basis for for an an inspection inspection procedure procedure using using the the SLS SLS technique. technique. In work reported at last year’s QNDE meeting In work reported at last year's QNDE meeting [1], [1], aa first first step step in in the the modeling of the SLS technique was presented, which involves the formulation of a model of the SLS technique was presented, which involves the formulation of a model for for the transient response of an isotropic, homogeneous, linearly elastic half-space submitted transient response of an isotropic, homogeneous, linearly elastic half-space submitted to to aa pulsed pulsed laser laser line line source source operating operating in in the the thermoelastic regime. The formulation takes takes into into account account optical optical penetration penetration into into the the material material and arid thermal diffusion diffusion from the laser laser source, source, and and isis therefore therefore aa suitable suitable representation representation not not only only for for the the far field, field, but but also also for for the the field field near near the the source, source, where these effects effects become significant. significant. In the present paper, paper, we we report report the the progress progress made made in in the the analysis analysis of of the the interactions interactions of of the the previously obtained obtained laser laser generated generated field field with with surface-breaking surf ace-breaking cracks. cracks. 283 THEORETICAL APPROACH The development of a model for the SLS technique starts with the solution of the problem of laser generation of ultrasound in the presence of a discontinuity. As a first approach, we have considered the two dimensional problem of an infinitely long line thermoelastic laser source impinging on an isotropic, homogeneous, linearly elastic half-space with an infinitely long, mathematically sharp crack both perpendicular to the surface of the half-space and parallel to the line source. By virtue of linear superposition, the complete problem of obtaining the total field generated by a laser source impinging on a half-space in the presence of a surface breaking crack can be decomposed into two subproblems. The first one entails obtaining the so-called incident field which is generated by the laser source impinging on an uncra.cked half-space. The second involves the determination of the so-called scattered field, which is generated in the cracked half-plane by the application of tractions on the crack faces which are equal in magnitude and opposite in sign to the corresponding tractions due to the incident field in the uncracked half-plane. The Incident Field In previous work [1], we studied the generation of ultrasound by lasers and developed a theoretical model for the incident field generated by laser illumination in the thermoelastic regime which takes into account the effects of thermal diffusion and optical penetration. The necessity of including these mechanisms in the formulation in order to obtain an accurate description of the generated field near the laser source wa..s shown in the context of the modeling of the SLS technique. The problem of the incident field was treated as a one-way coupled thermoelastic problem in plane strain by using the thermal stress approximation which neglects the coupling of the elastic displacement field to the governing differential equation for the temperature [4]. The statement of the one-way coupled thermoelastic problem for the incident field based on the hyperbolic heat equation may be written as follows: 2 \7 v T J — —T J- — —T 92 J. K — — —n q C //V 2 u-f (A-f/^)V(V - u ) = pu + ,3VT (1) where T is the temperature, K is the thermal diffusivity, c is the heat propagation speed which ha..s been chosen equal to the longitudinal wave speed, q is the laser induced heat source, u is the displacement, j3 is the thermoelastic coupling constant: (3 = (3A+2//)aT, aT is the coefficient of linear thermal expansion and A, JJL stand for the Lame elastic constants. For a discussion on the appropriateness of the use of the hyperbolic heat equation in the modeling of laser generated ultrasound see reference [1]. A possible expression for the heat source induced by laser line illumination q was derived from the expression proposed by Spicer [7] for point illumination as: *>0 (2) where E is the energy of the laser pulse per unit length,./?^ is the surface reflectivity and k is the thermal conductivity, % is the extinction coefficient which controls the 284 0.2 0.3 0.4 0.5 time (|o.s) FIGURE 4. Comparison between the solution provided by the complete model (solid line) and the distribution of shear dipoles model (dotted line) for normal stress axx on a vertical plane at depth z — 1.0 mm for the near field (x — 0.1 mm) and the far field (x — 5.1 mm), respectively [1]. exponential decay with depth z of sub-surface sources arising from optical penetration, RG id the radius of the Gaussian distribution assumed for the cross section of the laser beam and v is the pulse rise time in the assumed temporal distribution of the laser pulse. Equations (1) and (2) with, the appropriate boundary and initial conditions are solved for the case of line illumination of an isotropic, homogeneous, linearly elastic half-space by a semi-analytical procedure [1]. The solution provided by the above formulation which accounts for the effects of both thermal diffusion and optical penetration was compared with simplified models available in the literature, in particular the shear traction dipole model [6]. This model is based on the intuitive notion that the actions of a local generation of a temperature field and the application of an elastic dipole should be expected to produce equivalent fields. The laser source is thereby reduced to a localized action in space and time. Although simple, this model is very useful since it can be understood as a fundamental solution in the sense that it can account for any distribution of the source in space and time by appropriate convolution. However, by definition this model neglects the thermoelastic nature of the source and therefore does not account for thermal diffusion and optical penetration. Consequently, ina.ccurate predictions of the field near the source should be expected. The comparison between the complete model and the distribution of dipoles allows to clearly identify the effects of thermal diffusion and optical penetration in the near field. Indeed, only the complete model is able to predict a special feature of the near field waveform: the so-called precursor. The precursor is a sharp, initial spike at the longitudinal arrival observed experimentally in measurements of the near field. It has been shown that the precursor is caused by the subsurface sources arising from thermal diffusion or optical penetration [3]. On the other hand, both models lead to undistingulshable solutions for the far field as expected (see Fig. 4). It should be pointed out that the laser generated waveforms exhibit a considerable sharpness which increases as the width of the laser line source or the duration of the pulse decreases [1]. The resulting relative high frequency content of the signal has some numerical implications in the computation of the scattered field as will be shown in the next section. 285 The Scattered Field In recent work, the interactions of the previously obtained laser generated field with surf ace-breaking cracks have been studied. According to the proposed theoretical approach, the scattered field is defined as the field generated in the cracked half-space by tractions acting on the faces of the crack such that, when added to the tractions generated by the incident field on the plane of the crack, the condition of traction free crack faces is satisfied by the total field. By taking into account symmetry of geometry and symmetry of normal tractions and anti-symmetry of shear tractions respectively, the problem in the half-space can be restricted to a quarter-space and the symmetric and anti-symmetric contributions can be obtained independently. Ea.ch of these two problems in the quarter space is treated as an isothermal elastic problem in plane strain, thereby assuming that the presence of the crack does not affect the propagation of heat. This assumption is considered to be realistic for small fatigue cracks and has proven to be sufficiently accurate. The scattered field has been obtained numerically by a direct frequency domain Boundary Element Method (BEM). The BEM is ideally suited for the treatment of unbounded domains since the radiation condition at infinity is naturally included in the formulation. As the BEM is based on an boundary integral equation formulation in which displacements and stresses everywhere in the domain are expressed in terms of their boundary values, only the boundary of the quarter-space needs to be discretized. As this boundary is infinite, it needs to be truncated somewhere for numerical computation purposesln order to select the location of the truncation point, the simplest approach is based on the following considerations [2]. a. It is well known that body waves exhibit geometrical attenuation. Therefore, in order to reduce the error of the truncation associated with this type of waves, the truncation point should be loca.ted far enough from the domain of interest for the contribution of the omitted part of the boundary to be negligible. b. On the other hand, Rayleigh surface waves in two dimensions do not decay with distance to the source. Consequently, the truncation of the boundary leads to considerable reflections. The criterion in this case is that these artificially generated reflections reach, the domain of interest outside the time window of interest. This approach, although effective, leads to quite large computational meshes. In addition, the sharpness of the incident signal previously pointed out imposes stringent conditions on the number of frequencies to be computed and the boundary element sizes required for stability of the numerical scheme. The combination of these two circumstances leads to a considerable computational cost, even if artificial damping is added to the material. Therefore, efforts have been made towards the development of an alternative approach that allows to reduce the size of the computational domain. In order to reduce the requirements related to the body waves, the infinite boundary element has been used. This element, proposed by Watson in the context of the BEM, reproduces the geometrical decay of the body waves [8], thereby reducing the truncation error and allowing to locate the truncation point closer to the domain of interest. On the other ha..nd, we are currently developing a rigorous correction for the truncation error associated with the Rayleigh surface wave. We expect that this im- 286 V erticdisplacement at receive > -H <D 0.4 0.4 00.4 .4 0.4 I III II II 0.3 00.3 .3 0.2 0.2 00.2 .2 0.1 0.1 0.1 0.1 0 00 u -0.1 cti -o. -0.1 --0.1 0.] -0.2 -0.2 --0.2 0.2 -0.3 -0.3 --0.3 0.2 § M V cti I 0.3 °' 3 °' 2 0o (L> - Lj 3 > -0.4 -0. 0 0.5 1 1.5 2 -0.4 0 --0.4 0.4 0.5 1 1.5 2 0 0.5 1 1.5 2 time \JJLS] [µs] time FIGURE signal at at receiver receiver simulated simulated for for three three different different positions positionsof ofthe thelaser laser FIGURE 5. 5. Characteristic time signal source relative to the the crack. crack. the model provement of the model will will both both allow allow to to significantly significantly reduce reducethe thesize sizeofofthe themesh meshand and provide additional stability to to the the numerical numerical scheme. scheme. Both Both contributions contributions will willresult resultinin the desired reduction of the the computational computational cost. cost. PRELIMINARY NUMERICAL NUMERICAL RESULTS RESULTS FOR FOR THE THE TOTAL TOTAL FIELD FIELD The total field field is obtained obtained by by superposition superposition of of the the incident incident arid and the the scattered scattered fields. In this paper we present some preliminary results for the simulation fields. present some preliminary results for the simulation ofof the the total field field at the the location location of the the receiver. receiver. Three Three representative representative positions positions of of the the laser laser source relative to to the the crack crack have have been been considered: considered: far far ahead ahead (I) (I) , , very very close closetoto (II) (II) and far behind (III) (III) the crack (see Fig. 1). Fig. 5 shows the simulated the crack (see Fig. 1). Fig. 5 shows the simulated time time signal signal at the receiver corresponding to to the the three three positions positions of of the the laser. laser. The The peak-to-peak peak-to-peak amplitude and the maximum frequency of the Rayleigh wave have been the maximum frequency of the Rayleigh wave have beenplotted plottedversus versus the SLS position (see Fig. 6). The The simulations simulations show show good good qualitative qualitative agreement agreement with with experimental observations. The The proposed proposed model model is is able able to to simulate simulate the the characteristic characteristic variations observed experimentally experimentally as the the SLS SLS passes passes over over the the defect. defect. It should should be be noted It noted that that the the difference difference between between the the amplitude amplitude level levelfar farahead aheadand and far behind behind the far the crack crack is is related related to to the the depth depth of of the the crack crackrelative relativeto tothe thecenter centerwavelength wavelength of the the generated of generated Rayleigh Rayleigh surface surface wave. wave. In In the the case case shown shown inin Fig. Fig.6,6,the thedepth depthofofthe the crack is is much much smaller smaller than crack than the the center center wavelength, wavelength, so so that that aa substantial substantial portion portion of of the the incident energy energy transmits incident transmits past past the the crack. crack. CONCLUSIONS CONCLUSIONS In this this paper, In paper, aa model model for for the the novel novel Scanning Scanning Laser Laser Source Source (SLS) (SLS)technique techniquefor for laser-based ultrasonic detection of small surf ace-breaking cracks has been laser-based ultrasonic detection of small surface-breaking cracks has been presented. presented. The cracked cracked test The test specimen specimen is is modeled modeled as as an an isotropic, isotropic, homogeneous, homogeneous, linearly linearly elastic elastic half-space with a two-dimensional, mathematically sharp surface-breaking half-space with a two-dimensional, mathematically sharp surface-breakingcrack, crack,which which is perpendicular perpendicular both both to is to the the direction direction of of scanning scanning and and the the free free surface surface of of the thehalf-space. half-space. The ultrasonic ultrasonic response The response of of the the cracked cracked half-space half-space to to aa pulsed pulsed laser laser line line source sourceoperatoperating in the thermoelastic regime is decomposed, by virtue of linear superposition, ing in the thermoelastic regime is decomposed, by virtue of linear superposition, into into the incident incident and the and the the scattered scattered fields, fields, which which can can be be obtained obtained separately. separately. The Theincident incident field is is generated generated by by the field the line line laser laser heat heat source source in in the the uncracked uncracked half-space. half-space. The Theformuformu- 287 10 j 0.7 0.7 crack crack maximum frequency [MHz] peak−to−peak amplitude [nm/mJ] 0.8 0.8 £. 0.6 0.6 I 0.5 0.4 0.4 0.3 0.3 2 0.2 i °- crack 8 6 4 2 f 0.1 0.1 0 0 11 22 33 44 0 0 5 SLS position position [mm] [mm] SLS 1 22 3 3 SLS position position [mm] [mm] SLS 4 4 5 FIGURE 6. 6. Simulated Simulated signatures signatures of ofthe the defect defect in in the the ultrasonic ultrasonic amplitude amplitude (left) (left) and and the the maximum FIGURE frequency (right) (right) of of the the generated generated signal signal as as the the laser laser source source scans scans over over aa surface-breaking crack. frequency lation takes takes into into account account the the effects effects of of thermal thermal diffusion diffusion from from the source and optical lation penetration into into the the material. material. The The corresponding thermoelastic problem is solved semipenetration analytically. The The resulting resulting model model provides provides an an accurate accurate simulation simulation of ofthe the near near field, field, while while analytically. the far field simulations show excellent agreement with, simplified models. The scatthe far field simulations show agreement with simplified tered field in the cracked half-space is obtained by a direct frequency domain boundary tered field in the cracked half-space is obtained by a direct frequency domain boundary element method. method. Preliminary Preliminary simulations simulations of of the the total total field field at at the the receiver location show element good qualitative agreement with SLS experimental observations. The next next step step is is to to good qualitative agreement with SLS experimental observations. The extract quantitative information from the theoretical model. extract quantitative information from the theoretical model. ACKNOWLEDGEMENTS ACKNOWLEDGEMENTS This work work was was carried carried out out in in the the course of of research funded by the Federal This Aviation Administration under Contract #DFTA 03-98-D-0008 through the Air TransAviation Administration under Contract #DFTA 03-98-D-0008 through portation Center of Excellence in Airworthiness Assurance. portation Center of Excellence in Airworthiness Assurance. REFERENCES REFERENCES Arias, I.I. and and Achenbach, Achenbach, J.D., J.D., in in Review Review of of Progress Progress in in QNDE, QNDE, vol. 21, pp. 324-331. 1.1. Arias, 2. Dominguez, J. Boundary Elements in Dynamics, Elsevier Applied Science Science Publishers Publishers 2. Dominguez, J. Boundary Elements in Dynamics, Elsevier Applied & Computational Mechanics Publications, London, 1993. & Computational Mechanics Publications, London, 1993. 3. Doyle, Doyle, P.A., P.A., Journal Journal ofof Physics Physics D, D, 19, 19, 1613-1623 1613-1623 (1986). (1986). 3. 4. 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