The research described in this thesis involves the design, development, and implementation of an automated positioning system for fiber-optic interferometric sensors. The Fiber-Tip Interferometer (FTI) is an essential component in the proven Thermo-Acousto-Photonic NDE technique for characterizing a wide range of engineering materials including polymers, semiconductors and composites. The need to adapt the fiber-optic interferometric system to an industrial environment and to achieve precision control for optimizing interferometric contrast motivated the development of an automated, self-aligning FTI system design. The design enables high-resolution positioning and alignment by eliminating manual subjectivity and allows significantly improved repeatability and accuracy to be attained. Opto-electronic and electromechanical devices including a GRIN lens, 2x2 fused bi-conical taper couplers, photodiodes, motor-controlled tip/tilt stages, oscilloscopes, and a PCI card, constitute a closed-loop system with a feedback controller. The system is controlled by and communicates with a computer console using LabVIEW, a graphical language developed by National Instruments. Specifically, alignment is quantified by scanning the voltage readings at various orientations of the GRIN lens. The experimental setup specific to achieving maximum interferometric contrast intensity when interrogating silicon wafers with various surface depositions is discussed. Results corresponding to the interferometric contrast data obtained at several different standoff distances (Fizeau Cavity magnitudes) demonstrate the robustness of the novel design.

This thesis investigates the use of a combined finite element and perfectly matched layer approach in modeling guided elastic wave motion in infinite plates and cylinders and its potential applications to non-destructive evaluation. Underlying principles of the per-fectly-matched, absorbing layer are demonstrated on one-dimensional wave propagation in a semi-infinite elastic rod. Feasibility of using the perfectly matched layer as absorbing boundary condition in the finite-element modeling of guided elastic wave propagation and scattering is studied for the canonical problem of shear horizontal wave motion in isotropic plates. Numerical re-sults in this study are validated against exact analytical solutions. Excellent agreement has motivated the endeavour to take the technique to the next level of pressure, shear-vertical wave motion in isotropic and transversely isotropic plates. Time-domain, finite-element formulation of the perfectly matched layer for pressure, shear-vertical wave motion was validated through comparisons with semi-analytical lit-erature data and reciprocity checks. Numerical implementation of the model was em-ployed in studying the effect of crack presence on the time of arrival in a pitch-catch, non-destructive inspection arrangement. Predictions made confirmed previously-reported experimental findings. Extensions into three-dimensional, Cartesian and cylindrical spaces were validated against reported data. Practical examples of wave scattering in damaged concrete beams, oil and gas pipelines, and composite shells demonstrated the potential use of the proposed model in simulating elastic-wave based non-destructive inspection. Up to 80 % of the computational time needed to run an extended-mesh, finite-element model can be saved by introducing the perfectly-matched, absorbing layer to the finite-element model as the current thesis proposes. This significant saving in computational time by the proposed FE-PML model can accelerate the production of artificial neural network training data or help tackle complicated non-destructive testing applications.

This thesis investigates the use of a combined finite element and perfectly matched layer approach in modeling guided elastic wave motion in infinite plates and cylinders and its potential applications to non-destructive evaluation. Underlying principles of the per-fectly-matched, absorbing layer are demonstrated on one-dimensional wave propagation in a semi-infinite elastic rod. Feasibility of using the perfectly matched layer as absorbing boundary condition in the finite-element modeling of guided elastic wave propagation and scattering is studied for the canonical problem of shear horizontal wave motion in isotropic plates. Numerical re-sults in this study are validated against exact analytical solutions. Excellent agreement has motivated the endeavour to take the technique to the next level of pressure, shear-vertical wave motion in isotropic and transversely isotropic plates. Time-domain, finite-element formulation of the perfectly matched layer for pressure, shear-vertical wave motion was validated through comparisons with semi-analytical lit-erature data and reciprocity checks. Numerical implementation of the model was em-ployed in studying the effect of crack presence on the time of arrival in a pitch-catch, non-destructive inspection arrangement. Predictions made confirmed previously-reported experimental findings. Extensions into three-dimensional, Cartesian and cylindrical spaces were validated against reported data. Practical examples of wave scattering in damaged concrete beams, oil and gas pipelines, and composite shells demonstrated the potential use of the proposed model in simulating elastic-wave based non-destructive inspection. Up to 80 % of the computational time needed to run an extended-mesh, finite-element model can be saved by introducing the perfectly-matched, absorbing layer to the finite-element model as the current thesis proposes. This significant saving in computational time by the proposed FE-PML model can accelerate the production of artificial neural network training data or help tackle complicated non-destructive testing applications.

This thesis is focused on non-contact air-coupled ultrasonic Non-Destructive Evaluation (NDE) of Carbon-Carbon (C/C) disc brake materials. The minimum detectable defect size in the C/C composite disc brakes up to the maximum thickness of 1 7/16" (36.33 mm) using 120, 225 and 400 kHz transducers was investigated in the experimental section of this thesis. The effect of scanning increment step size on resolution of the final C-scan image was also investigated. The results indicated that the 12.7 mm diameter flat bottom drilled holes were reliably detectable using 225 kHz transducers. The flat bottom drilled holes and the side drilled holes of 6.35 mm in diameter were detectable on the final C-scan images of 225 kHz testing mainly due to the known locations of the defects. Results showed that testing frequency of 120 kHz provides very transparent C-scans. Testing frequency of 225 kHz provides also good transparency and better resolution. Testing frequency of 400 kHz did not provide satisfactory results. No advanced signal filtering techniques were utilized during the experiments. The relationship between the speed of sound in C/C material and the carbon fiber orientation in the carbon matrix needs to be investigated. The air-coupled ultrasonic testing of the C/C composite disc brake samples was conducted at the Center for Non-Destructive Evaluation at Iowa State University.

An acousto-ultrasonic approach is used to explore the damage development in tensile shear spot welds during fatigue loading. There is reasonable data to support the hypothesis that a decrease in an AU signal is indicative of the presence of an internal crack and could be used for monitoring and evaluation purposes. / Master of Science

This report describes the results of computerized ultrasonic C-scanning of solid steel bridge pins using a raytrace model. The raytrace model was developed to facilitate interpretation of data obtained from an ultrasonic C-scanning system for the Virginia Transportation Research Council (VTRC). The report discusses the reasons behind the development of the raytrace model, as well as specifications of the model, the input conditions, and the data output and visualization. The model uses as input, various "boundary" conditions of the solid steel pin with reduced diameter pin ends, as well as size and location information of a flaw or a wear groove placed within the main pin body. The model considers sound beams to be composed of rays and calculates ray reflections/conversions. This is done until the ray returns to a receiver location or is lost due to exceeding the time-of-flight. Once the model has returned with the received ray data, it uses the receiver conditions provided (transducer used, size of scanning grid, grid resolution, etc.), and calculates a 2-Dimensional C-scan image for each particular depth/time selected. Using PV-Wave visualization software, it is possible to plot the values for each depth to view a color graph. This graphical plot can then be analyzed/compared with the field C-scans to determine the closest match of a flaw or a wear groove inside the bridge pin. This helps in deciding if the condition of the pin is acceptable. / Master of Science

The performance advances of radar-guided missiles have created a need for radome materials with improved strength, toughness, and thermal shock capabilities. Zirconium phosphate bonded silicon nitride (Zr-PBSN), which has a low and thermally stable dielectric constant, high rain erosion resistance and a low-cost processing method, has been developed for radome applications in advanced tactical missiles. Pressureless sintering reduces processing costs, but is untried for radome manufacturing. The tendency for catastrophic failure requires that each radome fabricated with this material/method be inspected for defects prior to use. Visible, thermographic and ultrasonic nondestructive evaluation (NDE) methods have been tested with Zr-PBSN discs containing fabricated flaws likely to be present in a radome. Ultrasonic C-scanning using a 0.25" diameter, 15 MHz focused transducer with a pulse-echo configuration was clearly superior at detecting cracks, delaminations, impurities, voids and porosity variation. A method for determining local porosity via the longitudinal elastic wave velocity was developed and can be incorporated into an ultrasonic scanning system. A system that uses a computer to perform all motion control, data acquisition, and data manipulation, but requiring a skilled operator for scan setup and interpretation of the data has been proposed. / Master of Science

Os modelos existentes de propagação de ondas de ultra-som em meios líquidos e sólidos consideram a geração e recepção das ondas produzidas por transdutores simulados segundo o modelo do pistão plano ou com excitações cuja amplitude varia radialmente no pistão. Esses modelos são simplificados e não explicam completamente o comportamento real de transdutores de ultra-som interagindo com líquidos e sólidos. As verificações experimentais de propagação da onda de ultra-som em meios líquidos mostram que a onda de borda é diferente da onda plana. Observa-se também a existência de outras ondas não previstas nos modelos anteriores. Essas ondas são conhecidas como ondas head. A utilização do método dos elementos finitos (MEF) para a modelagem de propagação de ondas de ultra-som, incluindo o transdutor piezelétrico, permite a obtenção de resultados realísticos, conseguindo assim descrever com maior precisão o comportamento do transdutor e das ondas de ultra-som se propagando em diferentes meios e interagindo com defeitos que se comportam como refletores. Apesar disso, os resultados desses modelos dependem das características precisas dos materiais que compõem o transdutor. O transdutor de ultra-som é composto por uma cerâmica piezelétrica, por camadas de casamento e de retaguarda que geralmente são compósitos de epóxi com alumina e epóxi com tungstênio respectivamente, e pelo encapsulamento. Neste trabalho é analisada a resposta transiente de um transdutor circular de 2 MHz, com diâmetro de 12,7 mm, banda larga. O modelo do transdutor foi implementado com o método de elementos finitos. A análise transiente pelo MEF é implementada com o software ANSYS. Na primeira parte do trabalho o transdutor é analisado no modo de transmissão em água. Os resultados do modelo com MEF foram comparados com os resultados do modelo do pistão plano e com verificações experimentais obtidas em tanque de imersão com um hidrofone tipo agulha. Na segunda parte é realizada a análise do transdutor operando em modo pulso-eco radiando em peças de teste com e sem defeito, utilizando acoplamento direto e acoplamento por buffer de água. Os resultados do MEF apresentam boa concordância com os resultados obtidos experimentalmente. / Simple models for ultrasonic wave propagation in liquid and solid media consider the wave generation and reception by transducers that behave as plane pistons. These models are simplified and they do not explain completely the behavior of an ultrasonic transducer when interacting with other media. Experimental verifications of ultrasonic wave propagation in liquid show that the pressure amplitude of the edge wave is different from the plane wave. Also it is observed the existence of other types of waves not foreseen in these previous models. These waves are known as head waves. More realistic models for ultrasonic wave propagation are obtained using the finite element method (FEM). These models include the piezoelectric transducer, thus, describing with higher precision the behavior of the transducer and the ultrasonic waves propagating in different mediums and interacting with defects. The precision of the models depends on the accurate determination of the mechanical and electrical properties of the involved materials. The ultrasonic transducer is composed by a piezoelectric ceramic, a matching layer and a backing layer that are generally made by epoxy/alumina and epoxy/tungsten composites respectively. In this work it is analyzed the transient response of a circular transducer of 12.7 mm diameter and 2 MHz center frequency. The transducer model was implemented with the finite element method. The FEM transient analysis was executed in the ANSYS software. In the first part of the work the transducer is analyzed in transmission mode in water and the MEF results are compared with the plane piston model and with experimental verifications using a hydrophone. In the second part it is carried at the transducer analysis operating in pulse-echo mode radiating into test pieces with and without defects, using direct and water buffer coupling. The MEF results show good agreement with the results obtained experimentally in the laboratory.

Os modelos existentes de propagação de ondas de ultra-som em meios líquidos e sólidos consideram a geração e recepção das ondas produzidas por transdutores simulados segundo o modelo do pistão plano ou com excitações cuja amplitude varia radialmente no pistão. Esses modelos são simplificados e não explicam completamente o comportamento real de transdutores de ultra-som interagindo com líquidos e sólidos. As verificações experimentais de propagação da onda de ultra-som em meios líquidos mostram que a onda de borda é diferente da onda plana. Observa-se também a existência de outras ondas não previstas nos modelos anteriores. Essas ondas são conhecidas como ondas head. A utilização do método dos elementos finitos (MEF) para a modelagem de propagação de ondas de ultra-som, incluindo o transdutor piezelétrico, permite a obtenção de resultados realísticos, conseguindo assim descrever com maior precisão o comportamento do transdutor e das ondas de ultra-som se propagando em diferentes meios e interagindo com defeitos que se comportam como refletores. Apesar disso, os resultados desses modelos dependem das características precisas dos materiais que compõem o transdutor. O transdutor de ultra-som é composto por uma cerâmica piezelétrica, por camadas de casamento e de retaguarda que geralmente são compósitos de epóxi com alumina e epóxi com tungstênio respectivamente, e pelo encapsulamento. Neste trabalho é analisada a resposta transiente de um transdutor circular de 2 MHz, com diâmetro de 12,7 mm, banda larga. O modelo do transdutor foi implementado com o método de elementos finitos. A análise transiente pelo MEF é implementada com o software ANSYS. Na primeira parte do trabalho o transdutor é analisado no modo de transmissão em água. Os resultados do modelo com MEF foram comparados com os resultados do modelo do pistão plano e com verificações experimentais obtidas em tanque de imersão com um hidrofone tipo agulha. Na segunda parte é realizada a análise do transdutor operando em modo pulso-eco radiando em peças de teste com e sem defeito, utilizando acoplamento direto e acoplamento por buffer de água. Os resultados do MEF apresentam boa concordância com os resultados obtidos experimentalmente. / Simple models for ultrasonic wave propagation in liquid and solid media consider the wave generation and reception by transducers that behave as plane pistons. These models are simplified and they do not explain completely the behavior of an ultrasonic transducer when interacting with other media. Experimental verifications of ultrasonic wave propagation in liquid show that the pressure amplitude of the edge wave is different from the plane wave. Also it is observed the existence of other types of waves not foreseen in these previous models. These waves are known as head waves. More realistic models for ultrasonic wave propagation are obtained using the finite element method (FEM). These models include the piezoelectric transducer, thus, describing with higher precision the behavior of the transducer and the ultrasonic waves propagating in different mediums and interacting with defects. The precision of the models depends on the accurate determination of the mechanical and electrical properties of the involved materials. The ultrasonic transducer is composed by a piezoelectric ceramic, a matching layer and a backing layer that are generally made by epoxy/alumina and epoxy/tungsten composites respectively. In this work it is analyzed the transient response of a circular transducer of 12.7 mm diameter and 2 MHz center frequency. The transducer model was implemented with the finite element method. The FEM transient analysis was executed in the ANSYS software. In the first part of the work the transducer is analyzed in transmission mode in water and the MEF results are compared with the plane piston model and with experimental verifications using a hydrophone. In the second part it is carried at the transducer analysis operating in pulse-echo mode radiating into test pieces with and without defects, using direct and water buffer coupling. The MEF results show good agreement with the results obtained experimentally in the laboratory.

Friction stir welding (FSW) is an advantageous solid-state joining process, suitable for many materials in the energy, aerospace, naval and automotive industries. Like all other welding processes, friction stir welding requires non-destructive evaluation (NDE). The time and resources to preform NDE is expensive. To reduce these costs, nontraditional NDE methods are being developed for FSW. Spectral based defect recognition uses the forces during the welding process to validate weld quality. Although spectral NDE methods have shown promise as an alternative NDE processes, many research welding speeds do not correspond to manufacturing speeds, nor do they explain the relationship between the spectral data and the process. The purpose of this work is to explore the possibility of acquiring additional information about the defect. Namely the defect’s type, location, and magnitude. In this study, welds with “wormhole” defects were produced at 2000, 2500 and 3000 mmpm in 5754 aluminum. The welding process forces and torque were measured and analyzed spectrally. The welded plates were then imaged with x-ray photography, a validated NDE method. It was found that low frequencies (0 – 4 Hz) in the y & z force signals correlate with defect presence in high speed FSW. In addition, the strong correlation between the spectral data and the presence of a defect allowed for defect magnitude predictions. Linear fits were applied to the defect measurements and the spectral data. Large error inhibits the wide use of this prediction method.