Optimizing linear phased array transducers for non-destructive evaluation of thin layers

In this work, a numerical method is proposed in order to achieve design optimisation of phased array (PA) probes for the special application of defects detection in thin films. This approach relies on an extended Fourier-based model that was adapted to predict the two-dimensional ultrasonic displacement field taking place in a thin plate under individual excitation of PA probe elements which have arbitrary orientation with respect to the examined part surface. Excitation is applied through a fluid couplant and is operated at scheduled delays that are managed to enable emission of constructive pulses. This gives the possibility to steer sound waves towards a direction and to focalize the beam in a selected point. An optimisation algorithm based on the concept of pattern search that does not require evaluation of a gradient was used to find the best match in the multidimensional analysis space of possibilities including the elements orientation angles, the elements lengths, the inter-elements distances and work frequency. Optimisation was performed with the objective to maximize the displacement amplitude at the focal point while minimizing simultaneously the effect of beam side lobes. The results obtained by this approach reveal that focalisation can be achieved with enhanced features in comparison with previous algorithms assuming linear elements that are parallel to the surface of the plate.