Exploring the feasibility of crack detection in plate weldments through an interposed layer of viscoelastic material.
Development of new approaches in the nondestructive evaluation of welded steel plates for large naval structures continues to be an area of interest for the DoD and the military complex. In this report we will evaluate an elastic-microwave based detection and imaging method using both numerical finite element (3D FEM) and experimental methods. The evaluation was performed on two test articles that were designed to represent critical structural components with flaws of interest. Details of the materials and the mechanical drawings were provided with the test articles. Flaws, cracks and weld defects have been included in the test articles to determine detection sensitivity and accuracy of the proposed method. Our approach uses a microwave interferometer (MI) to record the scattered response of flaws in the steel plated as it is driven by an incident elastic field. The MI can “see” (penetrate) through the viscoelastic coating to the upper surface of the plate. Out-of-plane displacement amplitudes of 10nm in the frequency range (1kHz to 25kHz) are readily observable, with the key feature being, that the surface bond between the coating and the steel plate are undisturbed. The non-contact aspect of the interferometer allows for large surface regions to be accurately and efficiently scanned in space and time. Spatiotemporal data sets of this kind and specialized wavefield processing provide powerful detection and imaging modalities. From these wavefield data sets, a plate thickness mapping capability has been demonstrated that can detect thickness changes on the order of 0.79 mm (1/32”) with spatial resolution on the order of the spatial sampling rate, 15mm (~5/8”). We have also shown that a topological energy analysis of the wavefield data can detect and locate small flaws, on the order of 5-10 mm (0.025-0.40”) in the welded joint of a 1.5” thick T-plate. As before, these results are obtained through a 2” thick viscoelastic coating without altering the integrity of coating or the coating bond. These results show that we are detecting and locating damage (flaws) in the plate that are much smaller than the wavelength of the propagating guided modes. Classical scattering theory places a (λ/2) resolution limit on the detectability of flaws in terms of the incident field [22], however, since the spatial resolution of the scanned region is much smaller, (Δx=Δy=15mm) and the inherent natural focusing of the time reversal operation, we are able to detect smaller flaws on the order of (λ/10). It is important to realize that we are not imaging the flaw but detecting and localizing a difference between a reference (pristine) sample and the measured (damaged) sample, relative to a spatial grid on the surface. The current scan resolution is 15mm x 15mm. At present we cannot expect to resolve individual flaws within a grid space only their cumulative effect. Even with the current limitations, this imaging approach appears to be a promising alternative to current methods where the coating layer is removed.