Immunity of the second harmonic shear horizontal waves to adhesive nonlinearity for breathing crack detection

High-order harmonic guided waves are sensitive to micro-scale damage in thin-walled structures, thus, conducive to its early detection. In typical autonomous structural health monitoring (SHM) systems activated by surface-bonded piezoelectric wafer transducers, adhesive nonlinearity (AN) is a non-negligible adverse nonlinear source that can overwhelm the damage-induced nonlinear signals and jeopardize the diagnosis if not adequately mitigated. This paper first establishes that the second harmonic shear horizontal (second SH) waves are immune to AN while exhibiting strong sensitivity to cracks in a plate. Capitalizing on this feature, the feasibility of using second SH waves for crack detection is investigated. Finite element (FE) simulations are conducted to shed light on the physical mechanism governing the second SH wave generation and their interaction with the contact acoustic nonlinearity (CAN). Theoretical and numerical results are validated by experiments in which the level of the AN is tactically adjusted. Results show that the commonly used second harmonic S0 (second S0) mode Lamb waves are prone to AN variation. By contrast, the second SH0 waves show high robustness to the same degree of AN changes while preserving a reasonable sensitivity to breathing cracks, demonstrating their superiority for SHM applications.

Numerical investigations into Nonlinear Vibro-ultrasonics and Surface Vibration Comparison method for detection of defects in a composite laminate

This paper begins with a numerical study based on earlier experiments of nonlinear vibro-ultrasonic behaviour of a composite laminate with a delamination defect upon sinusoidal linear sweep signal excitation . A methodology to model laminates with cross-ply layup is presented which can be extended to any layup if desired. In comparison to experiments where it is challenging to visualize the fine details of vibrations, simulations make it easier to visualize and helps in optimizing the defect probing methods. The paper goes on to discuss with the help of numerical results that a separation gap between the delamination surfaces occurs to be a common cause for the failure of nonlinear vibro-ultrasonic methods to detect delamination defects. This constraint can often be overcome with application of higher excitation amplitudes as has been demonstrated in several experimental works. However in this study, a new approach named Surface vibration comparison method (SVCM) to probe delamination defects in the absence of contact acoustic nonlinearity is proposed as a proof-of-concept. The technique is then evaluated for detection of weak kissing bond defects in composite beam specimens. Both the experimental and simulation results show potential of the method as damage detection technique in thin composite structures.

Experimental Verification of Contact Acoustic Nonlinearity at Rough Contact Interfaces

When a longitudinal wave passes through a contact interface, second harmonic components are generated due to contact acoustic nonlinearity (CAN). The magnitude of the generated second harmonic is related to the contact state of the interface, of which a model has been developed using linear and nonlinear interfacial stiffness. However, this model has not been sufficiently verified experimentally for the case where the interface has a rough surface. The present study verifies this model through experiments using rough interfaces. To do this, four sets of specimens with different interface roughness values (Ra = 0.179 to 4.524 μm) were tested; one set consists of two Al6061-T6 blocks facing each other. The second harmonic component of the transmitted signal was analyzed while pressing on both sides of the specimen set to change the contact state of the interface. The experimental results showed good agreement with the theoretical prediction on the rough interface. The magnitude of the second harmonic was maximized at a specific contact pressure. As the roughness of the contact surface increased, the second harmonic was maximized at a higher contact pressure. The location of this maximal point was consistent between experiments and theory. In this study, an FEM simulation was conducted in parallel and showed good agreement with the theoretical results. Thus, the developed FEM model allows parametric studies on various states of contact interfaces.

Numerical Simulation on Micro-damage Detection In CFRP Composites Based on Nonlinear Ultrasonic Guided Waves

Micro-damages such as pores, closed delamination/debonding and fiber/matrix cracks in carbon fiber reinforced plastics (CFRP) are vital factors towards the performance of composite structures, which could collapse if defects are not detected in advance. Nonlinear ultrasonic technologies, especially ones involving guided waves, have drawn increasing attention for their better sensitivity to early damages than linear acoustic ones. The combination of nonlinear acoustics and guided waves technique can promisingly provide considerable accuracy and efficiency for damage assessment and materials characterization. Herein, numerical simulations in terms of finite element method are conducted to investigate the feasibility of micro-damage detection in multi-layered CFRP plates using the second harmonic generation (SHG) of asymmetric Lamb guided wave mode. Contact acoustic nonlinearity (CAN) is introduced into the constitutive model of micro-damages in composites, which leads to the distinct SHG compared with material nonlinearity. The results suggest that the generated second order harmonics due to CAN could be received and adopted for early damage evaluation without matching the phase of the primary waves.

Scattering analysis of nonlinear Lamb waves at delaminations in composite laminates

This study investigates the higher harmonic generation of the Lamb wave at a delamination due to contact acoustic nonlinearity, which is a clapping phenomenon between sublaminate surfaces due to the Lamb wave interaction with the delamination. In this study, higher harmonics of the Lamb wave induced at the delamination in composite laminates are studied in detail. This study performs both numerical and experimental studies. A three-dimensional finite element model is proposed for predicting the propagation of nonlinear Lamb waves in composite laminates and is verified using experimentally measured data. The results show the proposed numerical model can reasonably predict higher harmonic generated by contact acoustic nonlinearity. It is found that the delamination is the major source of contact acoustic nonlinearity in the composite laminates. A mode conversion study is also carried out to gain further physical insight into the higher harmonic generation of the Lamb wave at the delamination.

Characterization of Microcrack Orientation Using the Directivity of Secondary Sound Source Induced by an Incident Ultrasonic Transverse Wave

In this paper, characterization of the orientation of a microcrack is quantitatively investigated using the directivity of second harmonic radiated by the secondary sound source (SSS) induced by the nonlinear interaction between an incident ultrasonic transverse wave (UTW) and a microcrack. To this end, a two-dimensional finite element (FE) model is established based on the bilinear stress–strain constitutive relation. Under the modulation of contact acoustic nonlinearity (CAN) to the incident UTW impinging on the microcrack examined, the microcrack itself is treated as a SSS radiating the second harmonic. Thus, the directivity of the second harmonic radiated by the SSS is inherently related to the microcrack itself, including its orientation. Furthermore, the effects of the stiffness difference between the compressive and tensile phases in the bilinear stress–strain model, and the UTW driving frequency, as well as the radius of the sensing circle on the SSS directivity are discussed. The FE results show that the directivity pattern of the second harmonic radiated by the SSS is closely associated with the microcrack orientation, through which the microcrack orientation can be characterized without requiring a baseline signal. It is also found that the SSS directivity varies sensitively with the driving frequency of the incident UTW, while it is insensitive to the stiffness difference between the compressive and tensile phases in the bilinear stress–strain model and the radius of the sensing circle. The results obtained here demonstrate that the orientation of a microcrack can be characterized using the directivity of the SSS induced by the interaction between the incident UTW and the microcrack.