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This research focuses on the theoretical analysis, development and experimental evaluation of a water cooled Electromagnetic Acoustic Transducer (EMAT) specifically designed for high-temperature Guided Wave Testing (GWT). Its novel design and detailed calculation of its optimum operating conditions resulted in its effectiveness at high temperatures for both short (500oC) and long-term inspection (250oC). All the steps followed for the theoretical and experimental investigation of the limitations of the existing technology and the development of a probe that can overcome these boundaries are presented. Finite Element Analysis (FEA) was performed for the optimization of the EMAT design and estimation of its ultrasonic and thermal properties at room and high temperatures over time. The wave mode purity profile of the Periodic Permanent Magnet (PPM) EMAT was theoretically studied as well as the effect of temperature rise on its ultrasonic performance. Thermal and Computational Fluid Dynamics (CFD) analysis was accomplished for the EMAT design optimization and calculation of its optimum operating conditions. The experimental validation of the theoretical study was also accomplished. The novel water cooled EMAT was developed and experimentally evaluated regarding its ultrasonic and thermal response at room and high temperatures. An empirical method for the enhancement of EMAT performance and its SNR was established. The wave mode purity characteristics of PPM EMAT were experimentally investigated via Laser vibrometry tests, which agreed with FEA results. The impedance analysis and ultrasonic evaluation of the EMAT at both room and high temperatures against various operating conditions were linked and compared to the results obtained from the ultrasonic, thermal and fluid FEA. In all cases, the experimental study is in good agreement with the theoretical results.

Ground penetrating radar (GPR) technology has existed for many decades, but it has only been in the last 20 to 30 years that it has undergone great development for use in near surface ground investigations. The early 1980's saw the first major developments in the application of GPR for pavements (i.e. engineered structures designed to carry traffic loads), and it is now an established investigation technique, with generic information included in several national standard guidance documents. Analysis of GPR data can provide information on layer depths, material condition, moisture, voiding, reinforcement and location of other features. Assessing the condition of pavements, in order to plan subsequent maintenance, is essential to allow the efficient long-term functioning of the structure and GPR has enhanced and improved the range and certainty of information that can be obtained from pavement investigations. Despite the recent establishment of the technique in pavement investigation, the current situation is one in which GPR is used routinely for pavement projects in only a minority of countries, and the specialist nature of the technique and the sometimes variable results that are obtained can mean that there is both a lack of appreciation and a lack of awareness of the potential information that GPR can provide. The fact that GPR is still a developing technique, and that many aspects of its use are specialised in their nature, means that there are also several technical aspects of GPR pavement investigations which have not been fully researched, and knowledge of the response of GPR to some material conditions has not been fully established. The overall aim of this EngD research project was to provide improved pavement investigation capabilities by enhancing the methodologies and procedures used to obtain information from GPR. Several discrete research topics were addressed through various research methods including a literature review, fieldwork investigations, experimental laboratory investigations and a review of previously collected data. The findings of the research allowed conclusions and recommendations to be made regarding improved fieldwork methodologies, enhancing information and determining material condition from previously collected GPR data, assessing the effect of pavement temperature and moisture condition on GPR data and also on managing errors and uncertainty in GPR data. During the EngD project, a number of documents and presentations have been made to publicise the findings both within the EngD sponsoring company (Jacobs) and externally, and an in-house GPR capability has been established within Jacobs as a direct result of the EngD project.

This research investigates possible monitoring methods to non-invasively detect blockages in the cyclone of milk powder spray driers to avoid costly production shutdowns. Two possible solutions have been identified. These are guided wave and vibration analysis. This research focuses on vibration analysis method, based on variation in the natural frequencies and/or damping ratios caused by blockages. Experimental simulation studies the performance to assess the viability of the vibration analysis method in identifying blockage in the cyclone. To test this method, a 1.87m long vertical cylindrical steel tube with both ends simply supported was setup as a prototype and flour was used as the powder conveyed by the tube. Analytical, numerical and experimental methods were implemented on the prototype using vibration analysis techniques. Experimental resonant frequencies of the empty shell from the impact hammer excitation were compared with analytical and numerical solutions to analyse the modal shapes. The first bending mode was determined as 79 Hz, which decreased with the amount of added mass and location closer to the middle point. This was validated by the simulated mass experiment, which also matched with the beam-mass theory. Flour induced experiment further validated the variation of the first bending mode. Experimental 270Hz, 380Hz and 398Hz resonant frequencies increased with the amount of added mass, which was validated by the simulated mass and flour induced experiment. Besides the variation of the natural frequencies, the damping ratio was also studied and quantified using the Hilbert transform envelope curve method. Onsite monitoring of the vibration of the cyclone in a spray dryer was done at Fonterra Te Rapa and clear resonant frequencies were obtained. The research results from the prototype demonstrate that vibration analysis as a non-destructive method to detect the milk powder deposition or blockage in the cyclone is possible and promising. However, more work is required before industry application.

Pneumatic drives are an integral part of many machinery, with high demands on their reliability. Unfortunately, they sometimes fail, either due to improper production or assembly at the factory or by gradual degradation of moving parts and sealing elements during operation. Current diagnostic methods do not allow localization or identification of the type of damage and do not allow the operator to make a qualified decision. This work deals with the use of acoustic emission for these purposes. On PB type cylinders manufactured by Poličské strojírny a.s., a methodology is introduced which leads to the direct identification or at least localization of selected defects. By implementing this methodology in the final inspection of the production plant, the percentage of exposed pieces of waste will be increased, thus preventing accidents of these faulty pieces during operation.

In this thesis, two ultrasonic timing methods are used in order to investigate the accuracy and reliability of measurements for surface breaking cracks having different orientations and heights. Also the best applicable measurement technique is searched by comparing the received test results. These methods are the Time of Flight Diffraction (TOFD) Method using diffraction of longitudinal waves and another method using the reflection of shear waves from the crack tips. In order to simulate and measure the height of surface breaking cracks three sets of test blocks from steel, and two sets of wedges from plexiglas material are manufactured. Also several probes having frequencies of 2Mhz, 4Mhz, 5Mhz and angles of 45o and 70o are used. Some test procedures are created to make realistic comparisons between the test results and the ones found by previous studies in literature. The results are compared according to the standard deviations of errors in crack height measurements and it is found that the depth, orientation of defects and the frequency of probes have considerable affect on the results. With wider probe angles and higher frequencies of probes to some extent the errors are observed to be running low and the height of cracks could be measured closer to the original size. The amount of the errors is increased in measurements with the increasing angle of cracks. The results of both methods are found to be very satisfactory. A range of &plusmn / 0.5 mm for means of error from the original vertical crack heights is determined. The results agree with the previous studies.

La simulation opérationnelle a déjà été développée pour diverses activités dont l'exercice en conditions réelles peut s'avérer coûteux voire dangereux : le pilotage d'avion, les interventions chirurgicales, etc. L'idée consiste à remplacer la réalité par une simulation suffisamment réaliste pour donner l'impression aux utilisateurs qu'ils réalisent réellement l'activité.Le Contrôle Non-Destructif (CND) regroupe l'ensemble des méthodes mises en œuvre pour tester l'intégrité des pièces mécaniques sans les altérer. Dans ce domaine, la simulation opérationnelle n'a été introduite que très récemment par un brevet déposé par Airbus. Cette approche permet de simuler numériquement la présence de défauts sans avoir à les ajouter réellement dans les pièces. Les pièces aéronautiques étant coûteuses, la simulation opérationnelle permet de réduire les coûts liés à la formation des opérateurs, à l'évaluation des performances des méthodes ou aux tests en conditions réelles de nouvelles procédures.La présente thèse vise à développer les outils scientifiques et technologiques nécessaires à donner vie au concept de simulation opérationnelle en CND. Pour remplacer la réalité par la simulation, les défis à relever sont de trois ordres : le réalisme de la simulation, la rapidité des calculs et l'instrumentation. Nous avons choisi d'illustrer ces trois aspects dans le cadre de l'inspection par ultrasons de pièces en matériaux composites. Les modèles de simulation couramment employés --- basés sur la résolution des équations de la physique --- n'offrent pas des temps de calculs suffisamment courts pour satisfaire les pré-requis de la simulation opérationnelle. Par ailleurs, le réalisme des simulations souffre parfois de la difficulté à paramétrer correctement les modèles. Nous explorons donc une autre approche : les modèles sont construits à partir de données expérimentales. Cette stratégie est exploitée pour traiter différents types de phénomènes tels que l'endommagement par impact, le trou à fond plat ou encore les perturbations de la micro-structure des matériaux. Par ailleurs, une solution matérielle et logicielle sont proposées et un premier prototype de simulateur opérationnel est mis au point. Ce système permet d'exploiter les modèles développés et de montrer que les signaux synthétiques peuvent sembler aussi réalistes que la réalité. Cette thèse court ainsi du concept jusqu'au prototype. / Several fields have already adopted the concept of operational simulation to limit risks and costs. For instance, part of the training phase of airline transport pilots or surgerons can now rely on simulations instead of real-life situations.Non-Destructive Testing (NDT) assesses the integrity of structural and mechanical components without damaging them. Operational simulation has drawn attention of the NDT community only recently through an Airbus patent. In this field, the operational simulation can be used to simulate the presence of a defect in a component without actually inserting the defect. For expensive parts such as aeronautical structures, this approach can reduce the costs of training operators, evaluating NDT method performances or testing new procedures in real-conditions.This thesis work aims to apply the concept of operational simulation to NDT. Three main scientific and technological challenges are to be tackled: the simulation realism, the computation speed and the instrumentation. We chose to focus this study on the ultrasound NDT technique applied to composite materials. Classical simulation approaches based on physical equations are not fast enough for a real-time synthesis of ultrasound signals. Moreover, the realism is often limited by the fidelity of the inspection set-up description. For instance, the material properties are not always well-known and bring to a drop of realism. Thus, we investigate an alternative way: the models are built directly from experimental data. This strategy is applied to model the effect of several phenomena such as impact damages, flat bottom holes or material micro-structure. Hardware and software solutions are also studied to propose a first prototype. We have shown that the replacement of real signals by on-the-fly simulated ones is achievable: the simulation is realistic enough to be considered as reality by operators. thus, this thesis work brings the concept to a first prototype dedicated to ultrasound NDT.

<p>Non-destructive characterization of multi-layered structures that can be accessed from only a single side is important for applications such as well-bore integrity inspection. Collimated beam ultrasound systems are a technology for imaging inside multi-layered structures such as geothermal wells. These systems work by using a collimated narrow-band ultrasound transmitter that can penetrate through multiple layers of heterogeneous material. A series of measurements can then be made at multiple transmit frequencies. However, commonly used reconstruction algorithms such as Synthetic Aperture Focusing Technique (SAFT) tend to produce poor quality reconstructions for these systems both because they do not model collimated beam systems and  they do not jointly reconstruct the multiple frequencies.</p> <p><br></p> <p>In this thesis, we first propose a multi-frequency ultrasound model-based iterative reconstruction (UMBIR) algorithm designed for multi-frequency collimated beam ultrasound systems. The combined system targets reflective imaging of heterogeneous, multi-layered structures. For each transmitted frequency band, we introduce a physics-based forward model to accurately account for the propagation of the collimated narrow-band ultrasonic beam through the multi-layered media. We then show how the joint multi-frequency UMBIR reconstruction can be computed by modeling the direct arrival signals, detector noise, and incorporating a spatially varying image prior.</p> <p><br></p> <p>We also propose a ringing artifact reduction method for ultrasound image reconstruction that uses a multi-agent consensus equilibrium (RARE-MACE) framework. Our approach integrates a physics-based forward model that accounts for the propagation of a collimated ultrasonic beam in multi-layered media, a spatially varying image prior, and a denoiser designed to suppress the ringing artifacts that are characteristic of reconstructions from high-fractional bandwidth ultrasound sensor data.</p> <p><br></p> <p>Results using both simulated and experimental data indicate that multi-frequency UMBIR reconstruction yields much higher reconstruction quality than either single frequency UMBIR or SAFT. In addition, our results demonstrate the capability of our RARE-MACE method to suppress ringing artifacts and substantially improve the image quality over single frequency UMBIR and SAFT.</p>

The focus in this work is on the use of ultrasonic testing as a method for inspecting components manufactured through additive manufacturing (AM) processes. The research is rooted in the need for effective non-destructive testingtechniques that can adapt to the unique challenges posed by AM-produced materials, including complex defect geometries and surface conditions. Ultrasonic testing is a versatile form of non-destructive testing, offering theability to detect internal flaws, such as voids, cracks, and inclusions, with highprecision and in real-time. Unlike many competing methods, ultrasonic testing works on most types of materials. Ultrasonic testing has been applied forinspection purposes for a long time. Now with emerging manufacturing methods, there is a need for evaluation techniques to keep up with this development.New data processing algorithms open up possibilities of extracting more information from the acquired signal. The thesis provides a review of UT’s capabilities in detecting and classifyingdefects within AM components, with a particular emphasis on the subtletiesintroduced by the layer-by-layer construction method inherent to AM technologies. The work advances development and validation of simulation modelsaimed at predicting the ultrasonic response from manufactured defects. Thesemodels are crucial for understanding the interaction between ultrasound wavesand material anomalies, offering insights into the potential for enhanced defectdetection strategies. The research also explores the practical case of integrating UT into the quality assurance processes by relying on mathematical simulation rather than experimental data. The findings suggest avenues for the refinement of creation of inspection procedure, including the the use of meta-models to cheaply acquire worst-case scenario defects, to better accommodate the specificities of AM materials. / Den här avhandlingen handlar om ultraljudsprovning av additivt tillverkade metalkomponenter. Ultraljud är en av flera metoder som används för att detektera defekter i komponenter utan att förstöra komponenten i processen. Samlingsnamnet för dessa metoder är oförstörande provning. Oförstörande provning är en viktig pusselbit i samhällets säkerhet då det möjliggör identifiering och utvärdering av potentiella defekter i material, vilket förebygger olyckor och strukturella fel. Vidare är det en viktig del inom hållbar utveckling genom att maximera nyttjandet av komponenter då dessa inte behöver ersättas med ett överdrivet försiktigt underhållsintervall. Ultraljudsprovning fungerar genomatt ultraljud introduceras in i en komponent, varefter en givare registrerar ekon som uppstår när ljudvågorna interagerar med eventuella defekter. Detta möjliggör både lokalisering och storleksbedömning av defekter, t.ex. sprickor, bindfel eller porer. Resultaten av den här avhandlingen syftar till att ge förutsättningar för att förbättra tolkningen av dessa signaler, dels genom att experimentellt validera simuleringsmodeller, samt tillämpning av dessa modeller för att utveckla en metamodell för att prediktera amplitudsvaret från en mängd defekter inom en viss parameterrymd. Med verktyg som detta kan billigare inspektionsprocedurer möjliggöras genom att man till större del kan förlita sig på simulering av signaler snarare än att skaffa stort underlag med experimentell data. / <p>Paper A, B and C are not included in the eletronic version. Paper C is under submission.</p>

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