The field of restorative dentistry and the problem of ultrasonic airframe corrosion in aerospace are introduced as motivation for the construction of a miniature ultrasonic pulser/receiver. / A broadly applicable ultrasonic pulser and receiver system is developed. Two pulsers, a 5V square and a 100V spike, and a 52dB amplifier with a 57MHz 6dB bandwidth were constructed as a result. These battery powered devices are tailored for compatibility with a custom built wireless data transmission system, also driven by the same voltage. It is demonstrated that the new pulser/receiver is comparable to the commercial system in performance in certain areas. / The new pulsers/receiver and a commercial one are used in this work. The data is acquired and analyzed using LabView and Matlab. It is shown that the ultrasonic technique can be used to follow the reaction in time as well as to gauge the cure of dental composites. The current work in ultrasonic airframe corrosion detection is furthered and the wireless system's functionality is affirmed.

Concrete is the most widely used construction material in the world, so the assessment of damage in concrete is critical from the point of view of both safety and cost. Of particular interest are macro cracks that extend through the concrete cover of the reinforcement, which can potentially expose the reinforcement to corrosive elements. The high density of scatterers such as aggregate and voids in concrete makes quantitative imaging with coherent ultrasound difficult. As an alternative, this research focuses on diffuse energy based ultrasonic methods rather than coherent ultrasonic methods for crack depth assessment. Two types of ultrasonic measurements were made on real cracks formed under four point bending: one that focuses on time of flight measurements from an impactor; while the other uses the arrival time of maximum energy in a diffuse field excited by an impulsive load from a transducer. Each of these ultrasonic techniques is used to interrogate a macro crack in a concrete beam, and the results are compared to determine their accuracy and robustness. The actual crack depth is determined using direct surface measurements and a destructive dye-injected approach with drilled cores. The results suggest that the diffusion method, using a maximum energy approach, more accurately estimates the crack than visual inspection and impact echo methods, which overestimate the depth.

Nondestructive testing (NDT) uses different wave propagation modes to evaluate the internal structure of materials, revealing internal damage such as corrosion and fracturing that cannot be detected by traditional methods. Civil infrastructures are considered high priority assets in Ontario and Canada because of their value, high consequence of failure, and the continual influence of aging effects. Unexpected failure of infrastructure not only costs more than planned replacements but also results in increased safety risks. The in-situ condition assessment of civil infrastructure is critical for the successful implementation of maintenance and safety programs. Therefore, reliable nondestructive methods of inspection are required for the implementation of economical and efficient maintenance and asset management programs. Continuing technological developments in data collection, acquisition equipment, and data processing techniques have provided useful applications of nondestructive methods in many engineering fields. Among the many applications, this research study examines three applications of nondestructive testing in civil engineering: (1) condition assessment of construction joints in asphalt pavements, (2) average thickness evaluation of steel pipes, and (3) void and debonding detection in grouted steel tanks. The study on asphalt focuses on the improvement of the coupling system between the transducers and the asphalt surface, and the development of a new data processing technique to reduce user input and increase the reliability of the condition assessment of longitudinal joints. The current wavelet transmission coefficient (WTC) method requires user input, making the automatic data processing difficult. In the WTC method, the coupling between the transducers and the asphalt surface requires the use of epoxy and aluminum plates. This procedure is not practical for testing in-service roads. A new coupling mechanism using polyurethane foam to provide a spring action on the transducers and calibrated weights to generate a compression force was developed and showed good results, reducing the testing time by up to 50%. A new and robust data analysis methodology, called instantaneous transmission coefficient (ITC), is proposed based on measured instantaneous frequencies and damping ratios. The main advantage of the ITC procedure is that it can be performed automatically, reducing user input. A laboratory scale asphalt slab is used to evaluate the new methodology. Results show good agreement between the WTC and ITC measurements for both jointed and joint-free areas. The second study investigates the feasibility of the multichannel analysis of surface waves (MASW) technique for the evaluation of the average wall thickness of steel pipes. Electromagnetic NDT methods, such as the eddy current and the remote field testing, are common tools for thickness measurement of conductive materials. However, these methods give only localized results where measurements are made, making the process time consuming and inaccurate for assessing the full cross-sectional area of the pipe. Lamb waves have been used previously in the evaluation of steel pipes; however, the existing techniques require prior calibration to a theoretical wave mode, and their accuracy decreases with the length of the pipe evaluated due to wave attenuation effects. Preliminary results show the capability of the MASW test for providing reliable thickness information. The measured dispersion curves include information of fundamental modes and the higher modes, providing an improved characterization of the medium. Thicknesses between 3.2 mm and 12.7 mm are tested with an error of less than 2%. The third study explores the detection of voids in a steel tank filled with lightweight grout. A joint analysis of surface waves and Lamb waves is used for void detection and the identification of debonding conditions in a laboratory scale model of a steel tank filled with grout. Different configurations of the MASW method are conducted using an instrumented hammer (large wavelengths, 10 cm < λ < 25 cm) and a 50 kHz piezoelectric transmitter (small wavelengths, 5 cm < λ < 9 cm) as sources. The attenuation coefficient computed from the Fourier spectra of the measured signals indicates that the presence of a void has an effect on the propagation of the wave. The comparison between experimental and theoretical dispersion curves show that mainly Lamb waves are generated during the testing of the steel tank; thus, detecting the debonding conditions between the steel plate and the grout. Lamb modes are used successfully for detecting the presence of a void beneath the steel wall. The laboratory measurements are effective in the detection of the void, showing amplitudes up to 50% higher, likely because the deformation of the wall is attenuated by the grout.

This study investigates the effect of front surface roughness on ultrasonic echo amplitude. Experiments were carried out on specimens whose front surfaces are machined by milling machine. Machining parameters were changed in milling process in order to obtain desired roughness values and milling head was tilted to a very small angle to obtain periodic rough surfaces. Experiments were performed with these specimens having roughness value of 0.5, 4.5, 11, 26.5 &micro / m. Ra. The back surface roughness of all specimens was kept constant at 1.5 &micro / m Ra by grinding operation. 1.5, 2, 3, 4 mm. holes were drilled at constant depth and to same side of each specimen to represent reference discontinuities. Ultrasonic tests, using pulse echo technique were carried out to monitor echo amplitudes corresponding to different roughness values. The tests were also repeated by using different ultrasonic probes having different frequencies. For additional comparison, different couplants were used through the tests. The results showed that there was a significant increase in the reduction of the sound pressure level with the increase in the surface roughness. Although there was no uncertainty observed about not being able to detect discontinuity because of roughness but correct couplant and frequency selection has a positive effect on correctly sizing the discontinuity and at attenuation measurements. The results obtained with this work can be used as a guide for testing rough surfaces, predicting the effect on ultrasonic examination before testing and discontinuity detecting capability under rough surface conditions.

Following Carslaw [1] and as discussed by Becker et al [2], the diffusion of ultrasonic energy in cement-based aggregates follow the heat diffusion equation. However, due to the finite size of the discs used in experiments by Becker, ultrasound energy is contained within the body for a longer period of time, as compared to [2]. Though the energy content of the disc in reality would eventually decay to zero, due to leaks and other mechanisms, a theoretical study of perfectly adiabatic case is useful to compare the residual energy values to material properties. As a particular example, the input energy sees multiple phenomena inside the material during propagation. The residual energy is this a combined effect of the multiple scattering, dissipative and diffusive processes. This objective of this thesis is to study the relationship between the residual spectral density and specimen geometry. The effort further aims to attribute the difference in the residual spectral energy density values in materials of similar geometry to the varying material properties of the heterogeneous materials. Finally, a study of the error propagation in the estimation is presented, along-with an analytical relationship showing the value of spectral energy density for discs of finite radius and height. Ref: 1. H. S. Carslaw, J.C.J., Conduction of Heat in Solids. 2nd ed ed. 1986: Oxford University Press, USA. 520 2. Becker, J., L.J. Jacobs, and J. Qu, Characterization of cement-based materials using diffuse ultrasound. Journal of Engineering Mechanics, 2003. 129(12): p. 1478-1484.

The objective of this research is the pursuit of a better characterization method for the air voids - particularly air-entrained voids - in fresh cement-based materials through the use of ultrasonics. The use of air-entraining agents (AEA's) to incorporate a stable network of air voids into fresh cement paste is common practice in the concrete industry. These particular air voids significantly improve durability of hardened cement paste through mitigation of stresses associated with freezing and thawing cycles. It is understood that the performance of entrained air voids in cement paste is dependent on their size and distribution, or spacing factor. However, conventional methods for qualifying air content, such as the Pressure, Volume, and Gravimetric Methods, only measure total air volume and cannot assess size or spacing. In this investigation, using matched pairs of transducers, ultrasonic pulses were transmitted through fresh cement paste specimens (0.0\% up to 0.6\% AEA by weight of cement). The received signals were recorded every five minutes during the first six hours and then every fifteen minutes thereafter. Analysis shows strong distinctions between specimens with and those without the AEA. Further research is needed into the distinctions among specimens with the AEA. However, the data suggest correlations between Vicat setting times, heat of hydration, and autogenous strain and ultrasonic metrics such as pulse velocity and peak frequency of the signal. The findings of this research should be most appropriate as a foundation for an inversion process and improved air-entrainment detection methods.

Consumer demands are driving the current trend in the microelectronics industry to make electronic products that are miniature, fast, compact, high-density, reliable and low-cost. The use of surface mount devices (SMDs) has helped to decrease the size of electronic packages through the use of solder bump interconnections between the devices and the substrates/printed wiring boards (PWBs). Solder bumps act as not only mechanical, but also electrical interconnections between the device and the substrate/PWB. Common manufacturing defects ¨C such as open, cracked, missing, and misaligned solder bumps ¨C are difficult to detect because solder bumps are hidden between the device and the substrate/PWB after assembly. The reliability of packaged electronic devices in storage and usage is a major concern in the microelectronics industry. Therefore, quality inspection of solder bumps has become a critical process in the microelectronics industry to help ensure product quality and reliability. In this thesis, a methodology for quality evaluation and reliability study of solder bumps in electronic packages has been developed using the non-destructive and non-contact laser ultrasound-interferometric technique, finite element and statistical methods in this research work. This methodology includes the following aspects: 1) inspection pattern ¨C specific inspection patterns are created according to inspection purpose and package formats, 2) laser pulse energy density calibration ¨C specific laser pulse power and excitation laser spot size are selected in terms of package formats, 3) processing and analysis methods, including integrated analytical, finite element and experimental modal analyses approach, advanced signal processing methods and statistical analysis method, 4) approach combining modal analysis and advanced signal processing to improve measurement sensitivity of laser ultrasound-interferometric inspection technique, and 5) calibration curve using energy based simulation method and laser ultrasound inspection technique to predict thermomechanical reliability of solder bumps in electronic packages. Because of the successful completion of the research objectives, the system has been used to evaluate a broad range of solder bump defects in a variety of packaged electronic devices. The development of this system will help tremendously to improve the quality and reliability of electronic packages.

The objectives of this thesis are to develop and validate laser ultrasonic inspection methods for on-line testing of microelectronic devices. Electronic packaging technologies such as flip chips and BGAs utilize solder bumps as electrical and mechanical connections. Since they are located hidden from view between the device and the substrate, defects such as cracks, voids, misalignments, and missing bumps are difficult to detect using non-destructive methods. Laser ultrasonic inspection is capable of detecting such defects by utilizing a high power laser pulse to induce vibrations in a microelectronic device while measuring the out of plane displacement using an interferometer. Quality can then be assessed by comparing the vibration response of a known-good device to the response of the sample under inspection. The main limitation with the implementation of laser ultrasonic inspection in manufacturing applications is the requirement to establish a known-good reference device utilizing other non-destructive methods. My work will focus on developing a method to inspect flip chip devices without requiring a previously established reference. The method will automatically examine measurement data from a large sample set to identify those devices which are most similar. The selected devices can then be utilized to compose a hybrid reference signal which can be used for comparison and defect detection. Current trends in the electronic packaging industry continue to drive toward increased solder bump density, making it increasingly difficult to generate strong ultrasonic signals in these stiffer devices. To overcome this difficulty, I propose a new excitation method which places the source of ultrasound at the inspection location for each test point on the device surface. This ensures that the same power is available for each inspection location while also increasing the signal to noise ratio. The hardware implementation of this method reduces the system complexity and required automation, which can significantly reduce equipment cost and inspection time. The implementation of the proposed excitation method in conjunction with the use of a hybrid reference signal for defect detection will improve the utility of the laser ultrasonic inspection technique to on-line inspection applications where no other non-destructive methods are currently available.

Thesis (Ph. D.)--Electrical and Computer Engineering, Georgia Institute of Technology, 2008. / Committee Chair: Michaels, Jennifer; Committee Member: Habetler, Thomas; Committee Member: Jacobs, Laurence; Committee Member: Michaels, Thomas; Committee Member: Vachtsevanos, George.

Thesis (M.Eng.(Mechanical and Aeronautical Engineering))--University of Pretoria, 2008. / Includes bibliographical references.