A detailed investigation of novel air-coupled absorbers for use in a diesel engine exhaust-driven ammonia-water absorption system operating in extreme ambient conditions was conducted. Electrically driven vapor-compression systems are under scrutiny due to the environmental impact of synthetic refrigerants and the exacerbation of electric utility loads during peak demand periods. One alternative to vapor-compression systems is the absorption heat pump that uses environmentally benign working fluids and can be driven by a variety of heat sources, including waste heat and solar thermal processes. Direct air coupling of the absorber and condenser instead of indirect hydronic coupling can reduce absorption system size, complexity, and inefficiency, but materials compatibility issues with ammonia-water and the poor heat transfer properties of air present challenges. Heat and mass transfer modeling was used to predict the performance of round-tube corrugated-fin and compact tube-array absorbers designed for a 2.64-kW absorption chiller operated in high ambient temperature (51.7°C) conditions. A single-pressure ammonia-water test facility was constructed and used in conjunction with a temperature- and humidity-controlled air-handling unit to evaluate the absorbers at design and off-design operating conditions. Absorber performance was recorded over a range of air temperatures (35-54.4°C), air flow rates (0.38-0.74 m3 s-1), inlet solution temperatures (92-102°C), concentrated solution flow rates (0.006-0.010 kg s-1), and concentrated solution concentrations (38-46%). At design conditions, round-tube corrugated-fin absorbers of 394 and 551 Fins Per Meter (FPM) demonstrated comparable performance (Q394-FPM,exp = 4.521±0.271 kW; Q551-FPM,exp = 4.680±0.260 kW), and measured heat transfer rates were 0.7-1.9% AAD higher than those predicted through modeling. The measured heat transfer rate in the prototype tube-array absorber was significantly lower than the values predicted at design conditions (Qprot,exp = 2.22±0.24 kW; Qprot,mod = 4.33 kW). Maldistribution of the two-phase flow in the tube array is the probable cause of the disparity between the prototype absorber data and model predictions. Results from this investigation can be used to guide the development of air-coupled heat and mass exchangers for compact absorption heat pumps.

It is well known that liquid coupling agents, which are commonly used in conventional ultrasonic testing to couple an ultrasonic transducer to a solid specimen, cause a number of problems including inconsistency in results and slowness of the inspection. This is especially true when the specimen surface is rough, such as those in field concrete structures; here the solution involves time-consuming surface preparation to polish every single point of inspection, making it impractical to inspect field structures with conventional, contact methods. To address this issue, this thesis proposes a new, fully non-contact, air-coupled measurement setup in the mid to high ultrasonic frequencies (50-150 kHz). This advanced setup and measurement technique is evaluated by calculating the signal to noise ratio for different numbers of signal averages. In addition, the effect of the lift-off distance of the transducer over the sample is also investigated. Ultrasonic waves are generated and detected in this frequency range with a sufficiently high signal to noise ratio (SNR), which enables performing a fast scan with a small number of signal averages. Using this setup, phase velocity and attenuation of Rayleigh surface waves in a concrete specimen are first measured. Then, the air coupled ultrasound technique is used to detect dicontinuities such as cracks at a concrete joint and reinforcement bars in a concrete block. Also, the capability of the proposed technique for measuring depths of surface-breaking cracks using air-coupled generated Rayleigh waves is demonstrated. Since this measurement setup directly generates Rayleigh waves, most of the disadvantages in the techniques based on the impact-echo method can be avoided and thus data processing is much simpler than that in the impact-echo based techniques. The results of the measurements show that this setup is highly promising and a big advancement towards the rapid ultrasonic nondestructive testing on large-scale field concrete structures.

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.

Nondestructive testing (NDT) plays a more important role today in evaluating structural integrity of civil infrastructure. Impact-echo method (IE) is an effective stress wave based NDT method for locating defects in concrete structures. However, the contact requirement between sensor and concrete surface significantly limits the test speed and wide application of this method to large-scale structures such as bridges. Recent studies show the feasibility of air-coupled sensing, which eliminates the contact requirement and thus accelerates IE test. To further improve the test speed, a fully non-contact IE test using air-coupled sensing and excitation is investigated in this dissertation. This dissertation provides the theoretical basis required for developing an effective air-coupled IE method. For air-coupled sensing, 2D numerical simulations are first conducted to study the wave propagation in the air-solid system during IE tests. Visualized wavefield indicates that parabolic reflectors can effectively enhance the IE signal strength by focusing airborne IE waves to an air-coupled sensor. To maximize signal amplification, an analytical solution for the focused axial pressure response of a parabolic reflector with incident plane waves is derived. This solution is used to determine the reflector geometry that gives the highest focusing gain. For air-coupled excitation, a focused spark source with an ellipsoidal reflector is employed to excite stress waves in concrete. Numerical simulations and available nonlinear computer code (KZKTexas) are employed to investigate the reflector geometry that gives the highest stress wave excitation in solids. An acoustical muffler that works with the focused spark source is proposed to decrease the spark-induced noise level. The effect of source receiver spacing on received IE signals is studied. Simulated wavefield demonstrates that the mode shape of IE surface displacement distribution along the radial direction matches the Bessel function of the first kind (J0). Numerical 3D simulation results show the relation between focused IE signals and source receiver spacings, and indicate the spacing should be minimized to obtain better focused IE signal strength. Air-coupled IE test using through transmission setup is also investigated. / text

Non-destructive testing (NDT) plays an important role today in condition assessment of civil infrastructure. Among these NDT methods, the Impact-Echo (IE) method is widely used to determine the thickness of a plate structure and locate delaminations in concrete. The conventional IE test uses a contact impact source and a contact sensor, which limits the scanning speed. Recent studies show the feasibility of applying the air-coupled sensing technology to the IE test. With the contact requirement eliminated, a fully air-coupled NDT system can be realized to achieve rapid scanning on large scale structures. In this dissertation, the air-coupled IE test is first simulated using 2D finite element models. The numerical simulation results are validated by experimental measurements. It is shown that the airborne IE mode is a quasi-plane wave in air. A parabolic reflector is proposed to focus the airborne IE wave and amplify the air-coupled IE test signals. The focusing effect is validated by experimental results. By applying a parabolic reflector to the air-coupled sensor, it is found that large sensor lift-off height and source-receiver spacing can be used in the air-coupled IE test. The geometry of the parabolic reflector and source-receiver spacing are optimized using numerical simulations. A focused spark source is proposed as a non-contact source for the fully air-coupled test system. The spark source is first calibrated in an anechoic chamber. The feasibility of using the focused spark source for stress wave excitation is validated by experiments. A fully air-coupled testing system is realized by combining the air-coupled sensor and the air-coupled source. Experimental studies show that this system can measure surface wave and the IE mode. The fully air-coupled system is tested using a conventional IE test setup and a through transmission test setup. An acoustic muffler is introduced to suppress the acoustic noise from the spark source. Several advanced signal processing techniques to reduce the acoustic noises are also investigated. The air-coupled sensor has been adopted on a crawler NDT system for concrete inspection in a noisy field environment. / text

Nonlinear ultrasonic waves have demonstrated high sensitivities to various microstructural changes in metal including coherent precipitates; these precipitates introduce a strain field in the lattice structure. The thermal aging of certain alloy steels leads to the formation of coherent precipitates, which pin dislocations and contribute to the generation of a higher harmonics in an initially monochromatic wave. The objective of this research is to develop a robust technique to perform nonlinear Rayleigh wave measurements in metals using a non-contact receiving transducer. In addition a discussion about the data processing based on the two-dimensional diffraction and attenuation model is provided in order to calculate the relative nonlinearity parameter. A precipitate hardenable material, 17-4 PH stainless steel, is used to obtain different precipitation stages by thermal treatment and the influence of precipitates on the ultrasonic nonlinearity is assessed. Conclusions about the microstrucutural changes in the material are drawn based on the nonlinear Rayleigh surface wave measurement and complementary measurements of thermo-electric power, mircohardness and ultrasonic velocity. The results show that the nonlinearity parameter is sensitive to coherent precipitates in the material and moreover that precipitation characteristics can be characterized based on the obtained experimental data.

Delaminations in concrete bridge decks result primarily from corrosion of the reinforcing bars (or rebar). This corrosion leads to volumetric expansion of the rebar. When the rebar expands, concrete cracks, and there is a localized separation of the concrete cover from the underlying concrete. Impact-echo testing is an effective technique to map delaminations on concrete bridge decks. However, mapping speed is limited by necessary retrieval of the impactor for traditional tests. To achieve higher scanning speeds, it is advantageous to use both a non-contact measurement (air-coupled impact-echo) and disposable-impactor excitation. Disposable impactors have the potential advantage of achieving greater deck scanning speeds because they do not need to be retrieved, and they can also be used with air-coupled measurement systems. This thesis reports impact excitation of concrete using disposable impactors such as water droplets and ice balls. The impact characteristics of these impactors are compared with those of steel balls and chain links. Comparing the acoustic recordings on intact and delaminated concrete surface shows that water droplets and ice balls are able to excite flexural resonant modes associated with delamination defects. The use of water droplets and ice balls for shallow delamination detection in concrete is thus demonstrated.

The purpose of this study is to develop a non-contact air-coupled NDT method to identify and characterize surface-breaking cracks in concrete structures using surface wave transmission measurements. It has been found that the surface wave transmission (SWT) across a surface-breaking crack is related to the crack depth. However, inconsistence was noticed in surface wave transmission measurements. In this dissertation, the author first summarized limitations of the current SWT method for application to concrete structures, which include inconsistent sensor coupling, near-field effect of sensors, effects of crack width, external loading effect on surface wave transmission coefficient, and lack of a repeatable source. In this dissertation, the author attempts to find solutions to the aforementioned problems. First, non-contact air-coupled sensors were applied to the SWT method to reduce experimental errors caused by inconsistent coupling condition of conventional contact sensors. Air-coupled sensing enables reliable and consistent results, and significantly improves test-speed. Results from laboratory and field tests demonstrate effectiveness of air-coupled sensors. Second, appropriate sensor-to-source configurations are proposed to reduce undesirable effects: (i) the near-field effect of sensors around a crack, and (ii) contribution of multiple modes in a plate-like structure with a finite thickness. Near-scattering of surface waves interacting with a surface-breaking crack was investigated using numerical simulations (finite element method) and experimental studies over a wide range of the normalized crack depth (h/λ: crack depth normalized by wavelength of surface waves) and the normalized frequency-thickness ratio (f-H/CR: frequency-thick normalized by Rayleigh wave speed). Third, effects of external loadings on transmission coefficient of surface waves in concrete were investigated through a series of experimental studies. In the research, variation of the transmission coefficient is presented as a function of crack mouth opening displacement (CMOD). This provides a guideline on minimum CMOD to which the SWT method can be reasonably applied. In addition, the author experimentally demonstrates that using low-cost piezoceramic sensors is effective in generating consistent stress waves in concrete. Finally, the author demonstrates that the air-coupled SWT method developed in this study is effective for in-situ estimates of a surface-breaking crack in large concrete structures. / text

Circular air-coupled ultrasonic testing (ACUT) setup for the inspection of commercial carbon-carbon composite aircraft brake disks was developed in Intelligent Measurement and Evaluation Laboratory (IMEL) at Southern Illinois University Carbondale (SIUC). The developed test setup utilizes Airstar single channel air-coupled equipment and has only manual A-scan and B-scan capability. The developed ACUT technique is unique compared to the commercial C-scan ultrasonic systems and is proficient, fast, economically feasible, and easy to implement method particularly for the inspection of carbon-carbon (C/C) composites aircraft brake disks. Prior to conducting air-coupled measurements, wobble analysis was carried out. This was important because significant wobbling in the test setup can lead to the interference of the reflected and the incident beam which would result to inaccurate ultrasonic measurements. The measured deviation due to wobbling, surface profile of the disk, design, and experimental error were relatively small. Therefore, these errors were neglected while performing ACUT measurements. For ACUT measurements, several through-transmitted amplitude signals were recorded within the C/C brake disks manually. The images were then reconstructed using Matlab based on the through-transmitted amplitude signals. Finally, a comparison was drawn between the reconstructed images and the C-scan images of the C/C brake disks obtained from the commercial Airstar C-scan ACUT system. Like commercial C-scan ACUT image results, reconstructed images were also able to detect all defects in the commercial C/C brake disks which served for the system verification and validation. In addition, defect, non-defect, and suspected areas within the C/C brake disks were quantified with air-coupled measurement. For this, light microscopy was conducted for every sample made from each C/C brake disks at lower magnification of 10X. It was concluded that it is very difficult to assess the crack or delamination situation based on a 2D micrograph of one depth. Also, it was concluded that an internal porosity and micro-cracks may not be only factors that can be related to defects. Finally, an intelligent systems approach, specifically, fuzzy logic and artificial neural network (ANN) methodologies were implemented for the automatic defect detection in commercial C/C aircraft brake disks by using air-coupled ultrasonic results. For this, a multi-layer perceptron (MLP) with two hidden layers and a scaled conjugate gradient back-propagation (BP) learning algorithm was used for the ANN training. The network training process was performed in an off-line mode using the ANN toolbox in Matlab. The network training was repeated until a steady state was reached, where there was no further change in the synaptic weights. The ANN provided plausible results in detecting the defect areas for different C/C brake disks. It was also demonstrated that the system was able to learn the rules without knowing any algorithm for automatic defect detection.

Quality control and quality assurance of pavements is today primarily based on core samples. Air void content and pavement thickness are parameters that are evaluated. However, no parameter connected to the stiffness is evaluated. There is a need for fast and reliable test methods that are truly non-destructive in order to achieve an effective quality control and quality assurance of pavements. This licentiate thesis presents surface wave testing using air-coupled microphones as receivers. The measurements presented in this work are performed in order to move towards non-contact measurements of material stiffness. The non-contact measurements are compared to conventional accelerometer measurements in order to compare the noncontact measurements to a “reference test”. The two appended papers are focused on evaluating one parameter in each paper. In the first paper all equipment needed to perform non-contact measurements are mounted on a trolley in order to enable measurements while rolling the trolley forward. It is shown that rolling measurements can provide rapid and reliable measurements of the Rayleigh wave velocity over large areas. However, the measurements are shown to be sensitive to misalignments between the microphone array and the measured surface. An uneven surface can thus cause major errors in the calculated results. The second paper presents an alternative method to evaluate the thickness resonance frequency of a concrete plate. It is demonstrated how the established Impact Echo method can give erroneous results when aircoupled microphones are used as receivers. Instead a method based on backward wave propagation is introduced. It is demonstrated how waves with negative phase velocities can be identified in a narrow frequency span close to the thickness resonance. / <p>QC 20141128</p>