This research investigates the modeling of randomly distributed surface-breaking microcracks and their effects on higher harmonic generation in Rayleigh surface waves. The modeling is based on micromechanical considerations of rough surface contact. The nonlinear behavior of a single microcrack is described by a hyperelastic effective stress-strain relationship. Finite element simulations of nonlinear wave propagation in a solid with distributed microcracks are performed. The evolution of fundamental and second harmonic amplitudes along the propagation distance is studied and the acoustic nonlinearity parameter is calculated. The results show that the nonlinearity parameter increases with crack density and root mean square roughness of the crack faces. While, for a dilute concentration of microcracks, the increase in acoustic nonlinearity is proportional to the crack density, this is not valid for higher crack densities, as the microcracks start to interact. Finally, it is shown that odd higher harmonic generation in Rayleigh surface waves due to sliding crack faces introduces a friction nonlinearity.

Although several studies have proven the accuracy of using a non-contact, air-coupled receiver in nonlinear ultrasonic (NLU) Rayleigh wave measurements, inconsistent results have been observed when working with narrow specimens. The objectives of this research are first, to develop a 3D numerical finite element (FE) model which predicts nonlinear ultrasonic measurements and second, to apply the validated model on the narrow waveguide to determine causes of the previously observed experimental issues. The commercial FE-solver ABAQUS is used to perform these simulations. Constitutive law and excitation source properties are adjusted to match experiments conducted, considering inherent effects of the non-contact detection, such as frequency dependent pressure wave attenuation and signal averaging. Comparison of “infinite” and narrow width simulations outlines various influences which impair the nonlinear Rayleigh wave measurements. When the wave expansion is restricted, amplitudes of the fundamental and second harmonic components decrease more significantly and the Rayleigh wavefronts show an oscillating interaction with the boundary. Because of the air-coupled receiver’s finite width, it is sensitive to these edge effects which alter the observed signal. Thus, the narrow specimen adversely affects key factors needed for consistent measurement of material nonlinearity with an air-coupled, non-contact receiver.