Experimental and Numerical Investigation of the Use of Ultrasonic Waves to Assist Laser Welding.

This study evaluates the enhancement of laser welding using ultrasonic waves aimed at reorganising the intermetallic position in such a fashion that leads to increased mechanical properties of welds in battery pack assemblies for electric vehicles. The experiment employed 20 kHz and 40 kHz High-Power Ultrasound Transducers (HPUTs) in both contact and contactless modes. A simplified experimental configuration is suggested to represent conditions similar to those found in electric vehicle battery pack assemblies.

An Interactive Web-Based Platform for Support Generation and Optimisation for Metal Laser Powder Bed Fusion.

Powder bed fusion-laser beam (PBF-LB), a prevalent and rapidly advancing additive manufacturing (AM) technology nowadays, serves the industry by producing thin, complex, and lightweight components for various sectors, including healthcare, automotive, defence, and aerospace. However, this technology encounters challenges related to the construction of critical parts and the high overall process costs. Equally significant is the role of support structures in metal laser powder bed fusion (PBF-LB/M).

Support Structures Optimisation for High-Quality Metal Additive Manufacturing with Laser Powder Bed Fusion: A Numerical Simulation Study.

This study focuses on Metal Additive Manufacturing (AM), an emerging method known for its ability to create lightweight components and intricate designs. However, Laser Powder Bed Fusion (LPBF), a prominent AM technique, faces a major challenge due to the development of high residual stress, resulting in flawed parts and printing failures. The study's goal was to assess the thermal behaviour of different support structures and optimised designs to reduce the support volume and residual stress while ensuring high-quality prints.

Analytical Simulation of the Microbubble Collapsing in a Welding Fusion Pool.

This paper explains the use of remote ultrasound vibration at the optimum position and frequencies to vibrate plates under welding, with the aim of initiating cavitation in the molten pool area. It has been shown in the literature that ultrasound cavitation changes microstructure morphology and refines the grain of the weld. In practice, the plates are excited through narrow-band high-power ultrasound transducers (HPUTs).

Detection and Analysis of Corrosion and Contact Resistance Faults of TiN and CrN Coatings on 410 Stainless Steel as Bipolar Plates in PEM Fuel Cells.

Bipolar Plates (BPPs) are the most crucial component of the Polymer Electrolyte Membrane (PEM) fuel cell system. To improve fuel cell stack performance and lifetime, corrosion resistance and Interfacial Contact Resistance (ICR) enhancement are two essential factors for metallic BPPs. One of the most effective methods to achieve this purpose is adding a thin solid film of conductive coating on the surfaces of these plates.

An Artificial-Intelligence-Driven Predictive Model for Surface Defect Detections in Medical MEMS.

With the advancement of miniaturization in electronics and the ubiquity of micro-electro-mechanical systems (MEMS) in different applications including computing, sensing and medical apparatus, the importance of increasing production yields and ensuring the quality standard of products has become an important focus in manufacturing. Hence, the need for high-accuracy and automatic defect detection in the early phases of MEMS production has been recognized. This not only eliminates human interaction in the defect detection process, but also saves raw material and labor required.

Diagnostic Feature Extraction and Filtering Criterion for Fatigue Crack Growth Using High Frequency Parametrical Analysis.

Mooring systems are an integral and sophisticated component of offshore assets and are subject to harsh conditions and cyclic loading. The early detection and characterisation of fatigue crack growth remain a crucial challenge. The scope of the present work was to establish filtering and alarm criteria for different crack growth stages by evaluating the recorded signals and their features.

Improved Defect Detection of Guided Wave Testing Using Split-Spectrum Processing.

Ultrasonic guided wave (UGW) testing is widely applied in numerous industry areas for the examination of pipelines where structural integrity is of concern. Guided wave testing is capable of inspecting long lengths of pipes from a single tool location using some arrays of transducers positioned around the pipe. Due to dispersive propagation and the multimodal behavior of UGW, the received signal is usually degraded and noisy, that reduce the inspection range and sensitivity to small defects.

Application of Ultrasonic Guided Waves for Inspection of High Density Polyethylene Pipe Systems.

The structural integrity assessment of thermoplastic pipes has become an interesting area of research due to its elevated usage in the liquid/gas transportation industry. Ultrasonic guided wave testing has gained higher attention from industry for the inspection of elongated structures due to the reduced inspection time and cost associated with conventional non-destructive testing techniques, e.g.

Numerical investigation of design parameters for optimization of the in-situ ultrasonic fouling removal technique for pipelines.

Fouling build-up in engineering assets is a known problem and, as a solution, the application of power ultrasonic for in-situ fouling removal has gained much attention from the industry. Current state-of-the-art fouling removal includes the use of hydraulic, chemical and manual techniques. Much research has been conducted to advance the knowledge on the potential uses of ultrasonics across different fouling applications, primarily in reverse osmosis membranes and heat exchangers.

Characterization and Design Improvement of a Thickness-Shear Lead Zirconate Titanate Transducer for Low Frequency Ultrasonic Guided Wave Applications.

Thickness-shear transducers for guided wave testing have been used in industry for over two decades and much research has been conducted to improve the resolution and sensitivity. Due to a geometric feature of the current state-of-the art transducer, there is an out-of-plane component in the propagation direction of the fundamental shear horizontal mode which complicates the signal interpretation. In such case, complex signal processing techniques need to be used for mode discrimination to assess the structural health with higher precision.

Characterization of the Use of Low Frequency Ultrasonic Guided Waves to Detect Fouling Deposition in Pipelines.

The accumulation of fouling within a structure is a well-known and costly problem across many industries. The build-up is dependent on the environmental conditions surrounding the fouled structure. Many attempts have been made to detect fouling accumulation in critical engineering structures and to optimize the application of power ultrasonic fouling removal procedures, i.

Numerical modelling of acoustic pressure fields to optimize the ultrasonic cleaning technique for cylinders.

Fouling build up is a well-known problem in the offshore industry. Accumulation of fouling occurs in different structures, e.g.

Structural Health Monitoring of Above-Ground Storage Tank Floors by Ultrasonic Guided Wave Excitation on the Tank Wall.

There is an increasing interest in using ultrasonic guided waves to assess the structural degradation of above-ground storage tank floors. This is a non-invasive and economically viable means of assessing structural degradation. Above-ground storage tank floors are ageing assets which need to be inspected periodically to avoid structural failure.

A Pattern Recognition Approach to Acoustic Emission Data Originating from Fatigue of Wind Turbine Blades.

The identification of particular types of damage in wind turbine blades using acoustic emission (AE) techniques is a significant emerging field. In this work, a 45.7-m turbine blade was subjected to flap-wise fatigue loading for 21 days, during which AE was measured by internally mounted piezoelectric sensors.

Wave Mode Discrimination of Coded Ultrasonic Guided Waves Using Two-Dimensional Compressed Pulse Analysis.

Ultrasonic guided waves testing is a technique successfully used in many industrial scenarios worldwide. For many complex applications, the dispersive nature and multimode behavior of the technique still poses a challenge for correct defect detection capabilities. In order to improve the performance of the guided waves, a 2-D compressed pulse analysis is presented in this paper.

High Temperature Shear Horizontal Electromagnetic Acoustic Transducer for Guided Wave Inspection.

Guided Wave Testing (GWT) using novel Electromagnetic Acoustic Transducers (EMATs) is proposed for the inspection of large structures operating at high temperatures. To date, high temperature EMATs have been developed only for thickness measurements and they are not suitable for GWT. A pair of water-cooled EMATs capable of exciting and receiving Shear Horizontal (SH₀) waves for GWT with optimal high temperature properties (up to 500 °C) has been developed.

Increased range of ultrasonic guided wave testing of overhead transmission line cables using dispersion compensation.

Overhead Transmission Line (OVTL) cables can experience structural defects and are, therefore, inspected using Non-Destructive Testing (NDT) techniques. Ultrasonic Guided Waves (UGW) is one NDT technique that has been investigated for inspection of these cables. For practical use, it is desirable to be able to inspect as long a section of cable as possible from a single location.

Frequency-sweep examination for wave mode identification in multimodal ultrasonic guided wave signal.

Ultrasonic guided waves can be used to assess and monitor long elements of a structure from a single position. The greatest challenges for any guided wave system are the plethora of wave modes arising from the geometry of the structural element which propagate with a range of frequency-dependent velocities and the interpretation of these combined signals reflected by discontinuities in the structural element. In this paper, a novel signal processing technique is presented using a combination of frequency-sweep measurement, sampling rate conversion, and Fourier transform.

Elliptical-Tukey chirp signal for high-resolution, air-coupled ultrasonic imaging.

A new signal processing method, which uses a modified chirp signal for air-coupled ultrasonic imaging, is described. A combination of the elliptical and Tukey window functions has been shown to give a better performance than the Hanning windowing used in most pulse-compression algorithms for air-coupled applications. The elliptical-Tukey chirp signal provides an improvement in both the resolution of images and signal-to-noise ratios.

The application of time-frequency analysis to the air-coupled ultrasonic testing of concrete.

Air-coupled ultrasound has been used for the nondestructive evaluation of concrete, using broad bandwidth electrostatic transducers and chirp excitation. This paper investigates the benefits of using time-frequency analysis in such situations, for both waveform retrieval and imaging in the presence of low signal levels. The use of the short-term Fourier transform, the Wavelet transform, and the Wigner-Ville distribution all are considered, in which accurate tracking of the ultrasonic chirp signals is demonstrated.

Noncontact, high-resolution ultrasonic imaging of wood samples using coded chirp waveforms.

A noncontact ultrasonic inspection technique has been developed to study the properties of wood samples in air. The system makes use of two broad bandwidth capacitive transducers, combined with signal processing techniques. A coded chirp signal was used in the current application to provide a waveform that could be postprocessed to provide sufficient sensitivity for transmission across samples of wood.

A swept frequency multiplication technique for air-coupled ultrasonic NDE.

A new technique has been investigated for improving the signals that can be obtained in air-coupled nondestruction evaluation (NDE). This relies on the wide bandwidth available from polymer-filmed capacitive transducers. The technique relies on a swept-frequency "chirp" signal, which is transmitted from a transducer in air.

High-resolution, air-coupled ultrasonic imaging of thin materials.

This paper describes the use of a focused air-coupled capacitance transducer combined with pulse compression techniques to form high-resolution images of thin materials in air. The focusing of the device is achieved by using an off-axis parabolic mirror. The lateral resolution of the focused transducer, operating over a bandwidth of 1.