Search Results (8)

In the additive manufacturing (AM) process, dynamic fluctuations in process parameters often result in non-uniform grain sizes in the microstructures of fabricated components, which impairs their stability of mechanical performance. Consequently, the accurate identification of microstructures in AM titanium alloy components is essential for optimizing their mechanical reliability and prolonging their service life in engineering applications. An approach combining ultrasonic testing and deep learning is provided to address the demands for high efficiency and intelligent identification of diverse grain microstructures in AM titanium alloys. First, the Centroidal Voronoi Tessellations (CVT) algorithm was employed to construct three representative simulation models that replicate the characteristic grain microstructures of AM titanium alloys encompassing fine-grained, coarse-grained, and mixed-grained configurations. Subsequently, COMSOL Multiphysics software (v.6.3) was utilized to perform laser-induced ultrasonic Lamb wave (LIULW) testing simulations on the CVT-based microstructure models. Further, a comprehensive simulation dataset was established, including time-domain signals and their frequency-domain features of LIULW. This simulation dataset was then used to train a neural network with an improved architecture, aiming to enhance the discriminative capability for subtle differences in LIULW signals induced by varying grain sizes. Experimental validation results demonstrated that the proposed enhanced Lamb wave-DenseNet network achieved an overall recognition accuracy of 97.93% for the three distinct grain microstructure categories. Collectively, these findings confirm that the integrated method provides a robust theoretical framework and a practical technical solution for large-scale, engineering-level microstructure identification of AM titanium alloy components. This work not only bridges the gap between microstructural simulation and intelligent LIULW testing but also lays a foundation for quality control in high-volume AM of titanium alloy structural parts. Full article

There is extensive use of nondestructive test (NDT) inspections on aircraft, and many techniques nowadays exist to inspect failures and cracks in their structures. Moreover, NDT inspections are part of a more general structural health monitoring (SHM) system, where cutting-edge technologies are needed as powerful resources to achieve high performance. The high-performance aspects of SHM systems are response time, power consumption, and usability, which are difficult to achieve because of the system’s complexity. Then, it is even more challenging to develop a real-time low-power SHM system. Today, the ideal process is for structural health information extraction to be completed on the flight; however, the defects and damage are quantitatively made offline and on the ground, and sometimes, the respective procedure test is applied later on the ground, after the flight. For this reason, the present paper introduces an FPGA-based intelligent SHM system that processes Lamb wave signals using piezoelectric sensors to detect, classify, and locate damage in composite structures. The system employs machine learning (ML), specifically support vector machines (SVM), to classify damage while addressing outlier challenges with the Mahalanobis distance during the classification phase. To process the complex Lamb wave signals, the system incorporates well-known signal processing (DSP) techniques, including power spectrum density (PSD), wavelet transform, and Principal Component Analysis (PCA), for noise reduction, feature extraction, and data compression. These techniques enable the system to handle material anisotropy and mitigate the effects of edge reflections and mode conversions. Damage is quantitatively evaluated with classification accuracies of 96.25% for internal defects and 97.5% for external defects, with localization achieved by associating receiver positions with damage occurrence. This robust system is validated through experiments and demonstrates its potential for real-time applications in aerospace composite structures, addressing challenges related to material complexity, outliers, and scalable hardware implementation for larger sensor networks. Full article

This paper presents the use of noncontact ultrasound for the nondestructive detection of defects in two plastic plates made of polyamide (PA6) and polyethylene (PE). The aim of the study was to: (1) assess the presence of defects as well as their size, type, and orientation based on the amplitudes of Lamb ultrasonic waves measured in plates made of polyamide (PA6) and polyethylene (PE) due to their homogeneous internal structure, which mainly determined the selection of such model materials for testing; and (2) verify the possibilities of building automatic quality control and defect detection systems based on ML based on the results of the above-mentioned studies within the Industry 4.0/5.0 paradigm. Tests were conducted on plates with generated synthetic defects resembling defects found in real materials such as delamination and cracking at the edge of the plate and a crack (discontinuity) in the center of the plate. Defect sizes ranged from 1 mm to 15 mm. Probes at 30 kHz were used to excite Lamb waves in the slab material. This method is sensitive to the slightest changes in material integrity. A significant decrease in signal amplitude was observed, even for defects of a few millimeters in length. In addition to traditional methods, machine learning (ML) was used for the analysis, allowing an initial assessment of the method’s potential for building cyber-physical systems and digital twins. By training ML models on ultrasonic data, algorithms can distinguish subtle differences between signals reflected from normal and defective areas of the material. Defect types such as voids, cracks, or weak bonds often produce distinct acoustic signatures, which ML models can learn to recognize with high accuracy. Using techniques like feature extraction, ML can process these high-dimensional ultrasonic datasets, identifying patterns that human inspectors might overlook. Furthermore, ML models are adaptable, allowing the same trained algorithms to work on various material batches or panel types with minimal retraining. This combination of automation and precision significantly enhances the reliability and efficiency of quality control in industrial manufacturing settings. The achieved accuracy results, 0.9431 in classification and 0.9721 in prediction, are comparable to or better than the AI-based quality control results in other noninvasive methods of flat surface defect detection, and in the presented ultrasonic method, they are the first described in this way. This approach demonstrates the novelty and contribution of artificial intelligence (AI) methods and tools, significantly extending and automating existing applications of traditional methods. The susceptibility to augmentation by AI/ML may represent an important new property of traditional methods crucial to assessing their suitability for future Industry 4.0/5.0 applications. Full article

Despite the well-established nature of non-destructive testing (NDT) technologies, autonomous monitoring systems are still in high demand. The solution lies in harnessing the potential of intelligent structures, particularly in industries like aeronautics. Substantial downtime occurs due to routine maintenance, leading to lost revenue when aircraft are grounded for inspection and repairs. This article explores an innovative approach using intelligent materials to enhance condition-based maintenance, ultimately cutting life-cycle costs. The study emphasizes a paradigm shift toward structural health monitoring (SHM), utilizing embedded sensors for real-time monitoring. Active thin film piezoelectric materials are proposed for their integration into composite structures. The work evaluates passive sensing through acoustic emission (AE) signals and active sensing using Lamb wave propagation, presenting amplitude-based and frequency domain approaches for damage detection. A comprehensive signal processing approach is presented, and the damage index and damage size correlation function are introduced to enable continuous monitoring due to their sensitivity to changes in material properties and defect severity. Additionally, finite element modeling and experimental validation are proposed to enhance their understanding and applicability. This research contributes to developing more efficient and cost-effective aircraft maintenance approaches through SHM, addressing the competitive demands of the aeronautic industry. Full article

In the last few years, the application of adhesive joints has grown significantly. Adhesive joints are often affected by a specific type of defect known as weak adhesion, which can only be effectively detected through destructive tests. In this paper, we propose nondestructive testing techniques to detect weak adhesion. These are based on Lamb wave (LW) data and artificial intelligence algorithms. A dataset consisting of simulated LW time series extracted from single-lap joints (SLJs) subjected to multiple levels of weak adhesion was generated. The raw time series were pre-processed to avoid numerical saturation and to remove outliers. The processed data were then used as the input to different artificial intelligence algorithms, namely feedforward neural networks (FNNs), long short-term memory (LSTM) networks, gated recurrent unit (GRU) networks, and convolutional neural networks (CNNs), for their training and testing. The results showed that all algorithms were capable of detecting up to 20 different levels of weak adhesion in SLJs, with an overall accuracy between 97% and 99%. Regarding the training time, the FNN emerged as the most-appropriate. On the other hand, the GRU showed overall faster learning, being able to converge in less than 50 epochs. Therefore, the FNN and GRU presented the best accuracy and had relatively acceptable convergence times, making them the most-suitable choices. The proposed approach constitutes a new framework allowing the creation of standardized data and optimal algorithm selection for further work on nondestructive damage detection and localization in adhesive joints. Full article

Lamb wave-based damage detection technology shows great potential for structural integrity assessment. However, conventional damage features based damage detection methods and data-driven intelligent damage detection methods highly rely on expert knowledge and sufficient labeled data for training, for which collecting is usually expensive and time-consuming. Therefore, this paper proposes an automated fatigue crack detection method using Lamb wave based on finite element method (FEM) and adversarial domain adaptation. FEM-simulation was used to obtain simulated response signals under various conditions to solve the problem of the insufficient labeled data in practice. Due to the distribution discrepancy between simulated signals and experimental signals, the detection performance of classifier just trained with simulated signals will drop sharply on the experimental signals. Then, Domain-adversarial neural network (DANN) with maximum mean discrepancy (MMD) was used to achieve discriminative and domain-invariant feature extraction between simulation source domain and experiment target domain, and the unlabeled experimental signals samples will be accurately classified. The proposed method is validated by fatigue tests on center-hole metal specimens. The results show that the proposed method presents superior detection ability compared to other methods and can be used as an effective tool for cross-domain damage detection. Full article

This review article is focused on the analysis of the state of the art of sensors for guided ultrasonic waves for the detection and localization of impacts for structural health monitoring (SHM). The recent developments in sensor technologies are then reported and discussed through the many references in recent scientific literature. The physical phenomena that are related to impact event and the related main physical quantities are then introduced to discuss their importance in the development of the hardware and software components for SHM systems. An important aspect of the article is the description of the different ultrasonic sensor technologies that are currently present in the literature and what advantages and disadvantages they could bring in relation to the various phenomena investigated. In this context, the analysis of the front-end electronics is deepened, the type of data transmission both in terms of wired and wireless technology and of online and offline signal processing. The integration aspects of sensors for the creation of networks with autonomous nodes with the possibility of powering through energy harvesting devices and the embedded processing capacity is also studied. Finally, the emerging sector of processing techniques using deep learning and artificial intelligence concludes the review by indicating the potential for the detection and autonomous characterization of the impacts. Full article

A tactile position sensing system based on the sensing of acoustic waves and analyzing with artificial intelligence is proposed. The system comprises a thin steel plate with multiple piezoelectric transducers attached to the underside, to excite and detect Lamb waves (or plate waves). A data acquisition and control system synchronizes the wave excitation and detection and records the transducer signals. When the steel plate is touched by a finger, the waveform signals are perturbed by wave absorption and diffraction effects, and the corresponding changes in the output signal waveforms are sent to a convolutional neural network (CNN) model to predict the x- and y-coordinates of the finger contact position on the sensing surface. The CNN model is trained by using the experimental waveform data collected using an artificial finger carried by a three-axis motorized stage. The trained model is then used in a series of tactile sensing experiments performed using a human finger. The experimental results show that the proposed touch sensing system has an accuracy of more than 95%, a spatial resolution of 1 × 1 cm², and a response time of 60 ms. Full article