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Measuring and correlating the thermal conductivity and ultrasonic transmission of seven hot-brazed-bonded copper plates established a relationship between heat transfer and ultrasonic transmission properties of the bonds. This relationship permits the prediction of heat transfer characteristics from ultrasonic transmission tests.
A technique which utilizes ultrasonic radiation has been developed to measure residual stresses in metals. This technique makes it possible to detect and measure the magnitude of the principle stresses and also to obtain their direction. The velocities of ultrasonic waves in materials are measured as the time to travel a fixed path length, and the change in transit time is related to the applied stress. The linear relationship obtained allows a procedure based on this principle to be used for the measurement of residual stress using surface waves and shear waves. A method for plotting stress profiles through a material using surface waves uses varying frequencies for the ultrasonic wave. A limitation of the shear wave method is considered. The system used for this technique is called the Modified Time of Flight System.
The characteristics of an ultrasonic generator with magnetostrictive amplifiers are described. The generator was designed to supply an output power of about 400 watts at a consumption of about 1 kilowatt. The generator produces sound waves in the frequency range of 18 to 30 KHz. The circuit design is described and examples of the construction are illustrated. The generator is used to study different industrial processes such as the effect of ultrasonic radiation of the emulsification of liquids, the dispersion of solids, and ultrasonic filtration.
A process of apatite decomposition with sulfuric acid was studied under the influence of ultrasound in the phosphoric acid production process. The studies were carried out with and without ultrasonic fields in the reaction mixture, which resembled the mixing ratio used in technical production processes. Ultrasound with a frequency of 20 kHz and an intensity of 1 W/sq cm was used in the studies. A very favorable ultrasonic effect upon the degree of apatite decomposition was observed. The ultrasonic field affects the shape of byproduct gypsum crystals. In the H3PO4 production process without ultrasound, the byproduct gypsum crystallizes as long, thin needles which cause problems in filtration. In the trials involving the application of wound, gypsum crystallized in the form of small platelets possessing a favorable ratio of length to width.
The practical results obtained as a result of filtering industrial chemical solutions under continuous flow conditions with the aid of an ultrasonic filter are presented. The main part of the assembly consists of an ultrasonic generator with an output power of about 400 W and the filtration assembly, in which there is a magnetostrictive amplifier constructed for 20.5 kHz. In addition to ensuring a continuous flow of filtered solution, ultrasonic filters can be replaced or cleaned at intervals of time that are 8-10 times greater than in the case of mechanical filters. They yield considerably better results as far as the size of the filtered particles is concerned. The parameters on which filtration quality depends are also presented.
An experimental investigation was made of the application of holographic interferometry to the nondestructive detection of unbonded areas (flaws) in bonded panels. Flaw detection results were compared with results obtained with an ultrasonic flaw detector. Holography, with panel deformation accomplished by a reduction in ambient pressure, is less sensitive for flaws beneath 5 and 10 plies of boron-epoxy than the ultrasonic method, though it does have its operational advantages. A process for the manufacture of bonded panels which incorporate known unbonded areas was also developed. The unbonded areas were formed without the use of foreign materials, which makes the method suitable for the construction of reference standards for bonded panels whenever needed for the proper setup of ultrasonic flaw-detection instruments.
An acoustic instrument system is described as a feasible tool for remote measurement of structural velocities. The system involves measurement of the Doppler shift of ultrasonic sound as it is reflected from an oscillating plate. Measurements were performed in air with an ultrasonic frequency source of 42.5 kilohertz. The surface under investigation was a plexiglass plate oscillating sinusoidally at 10, 13, and 15 Hz. Data are presented to show that, in such a system, the measurement of the Doppler shift is dependent upon the acoustic pathlength between the sensing device and the oscillating surface, with the distance between maximum shifts being half the wavelength of the ultrasonic source.
Phonon-charge carrier interactions are studied as well as ultrasonic resonators. Sensitivity enhancement factors predicted by one dimensional resonator theory are verified and several sensitive ultrasonic experimental techniques are developed. Measurements are reported of an anomalous sign reversal of the acoustoelectric voltage in a CdS resonator. Applications of CdS as an ultrasonic power detector are described.
A program to improve the quality, reproducibility and reliability of nondestructive testing through the development of improved ASTM-type ultrasonic reference standards is described. Reference blocks of aluminum, steel, and titanium alloys were considered. Equipment representing the state-of-the-art in laboratory and field ultrasonic equipment was obtained and evaluated. Some RF and spectral data on ten sets of ultrasonic reference blocks were taken as part of a task to quantify the variability in response from nominally identical blocks. Techniques for residual stress, preferred orientation, and microstructural measurements were refined and are applied to a reference block rejected by the manufacturer during fabrication in order to evaluate the effect of metallurgical condition on block response.
Ultrasonic studies are described which are specifically directed toward the quantitative measurement of randomly located defects previously found in aluminum welds with radiography or with dye penetrants. Experimental radiographic studies were also made to optimize techniques for welds of the thickness range to be used in fabricating the External Tank of the Space Shuttle. Conventional and innovative ultrasonic techniques were applied to the flaw size measurement problem. Advantages and disadvantages of each method are discussed. Flaw size data obtained ultrasonically were compared to radiographic data and to real flaw sizes determined by destructive measurements. Considerable success was achieved with pulse echo techniques and with 'pitch and catch' techniques. The radiographic work described demonstrates that careful selection of film exposure parameters for a particular application must be made to obtain optimized flaw detectability. Thus, film exposure techniques can be improved even though radiography is an old weld inspection method.
The basic relationship of ultrasonic signal velocity to directional subsurface stress is reviewed. Inappropriateness of dependency on a single correlative value of constant for a three dimensional stress field in metallic materials is discussed. Implementation of conventional ultrasonic nondestructive testing capabilities integrated to provide a composite technique for the measurement of orthogonal stress components is described, and the procedures for performing the preparatory calibration and subsequent stress field measurements are presented. In conclusion, the prime effect of stress on ultrasonic signal velocity occurs only in the direction of material excitation or particle motion.
An ultrasonic cavitation method for restoring obliterated serial numbers has been further explored by application to articles involved in police cases. The method was applied successfully to gun parts. In one case portions of numbers were restored after prior failure by other laboratories using chemical etching techniques. The ultrasonic method was not successful on a heavily obliterated and restamped automobile engine block, but it was partially successful on a motorcycle gear-case housing. Additional studies were made on the effect of a larger diameter ultrasonic probe, and on the method's ability to restore numbers obliterated by peening.
A program to improve the quality, reproducibility and reliability of nondestructive testing through the development of improved ASTM-type ultrasonic reference standards is described. Reference blocks of aluminum, steel, and titanium alloys are to be considered. Equipment representing the state-of-the-art in laboratory and field ultrasonic equipment was obtained and evaluated. RF and spectral data on ten sets of ultrasonic reference blocks have been taken as part of a task to quantify the variability in response from nominally identical blocks. Techniques for residual stress, preferred orientation, and micro-structural measurements were refined and are applied to a reference block rejected by the manufacturer during fabrication in order to evaluate the effect of metallurgical condition on block response. New fabrication techniques for reference blocks are discussed and ASTM activities are summarized.
A heuristic mathematical basis was proposed for the experimental correlations found between ultrasonic propagation factors and fracture toughness factors in metallic materials. A crack extension model was developed wherein spontaneous stress (elastic) waves produced during microcracking are instrumental in promoting the onset of unstable crack extension. Material microstructural factors involved in the process are measurable by ultrasonic probing. Experimental results indicate that ultrasonic attenuation and velocity measurements will produce significant correlations with fracture toughness properties and also yield strength.
Two ultrasonic methods for nondestructive measurements of the depth of a case-hardened layer in steel are described. One method involves analysis of ultrasonic waves diffused back from the bulk of the workpiece. The other method involves finding the speed of propagation of ultrasonic waves launched on the surface of the work. Procedures followed in the two methods for measuring case depth are described.
Progress in the application of ultrasonic techniques to nondestructive measurement of mechanical strength of engineering materials is reviewed. A dormant concept in nondestructive evaluation (NDE) is invoked. The availability of ultrasonic methods that can be applied to actual parts to assess their potential susceptibility to failure under design conditions is discussed. It was shown that ultrasonic methods yield measurements of elastic moduli, microstructure, hardness, fracture toughness, tensile strength, yield strength, and shear strength for a wide range of materials (including many types of metals, ceramics, and fiber composites). It was also indicated that although most of these methods were shown feasible in laboratory studies, more work is needed before they can be used on actual parts in processing, assembly, inspection, and maintenance lines.
The interactive signal analysis and ultrasonic data collection system (ECHO1) is a real time data acquisition and display system. ECHO1 executed on a PDP-11/45 computer under the RT11 real time operating system. Extensive operator interaction provided the requisite parameters to the data collection, calculation, and data modules. Data were acquired in real time from a pulse echo ultrasonic system using a Biomation Model 8100 transient recorder. The data consisted of 2084 intensity values representing the amplitude of pulses transmitted and received by the ultrasonic unit.
A heuristic mathematical basis is proposed for the experimental correlations found between ultrasonic propagation factors and fracture toughness factors in metallic materials. A crack extension model is proposed wherein spontaneous stress (elastic) waves produced during microcracking are instrumental in promoting the onset of unstable crack extension. Material microstructural factors involved in this process are measurable by ultrasonic probing. Experimental results indicate that ultrasonic attenuation and velocity measurements will produce significant correlations with fracture toughness properties and also yield strength.