On-Line Corrosion Monitoring of Plate Structures Based on Guided Wave Tomography Using Piezoelectric Sensors

Corrosion is a major safety and economic concern to various industries. In this paper, a novel ultrasonic guided wave tomography (GWT) system based on self-designed piezoelectric sensors is presented for on-line corrosion monitoring of large plate-like structures. Accurate thickness reconstruction of corrosion damages is achieved by using the dispersive regimes of selected guided waves and a reconstruction algorithm based on full waveform inversion (FWI). The system makes use of an array of miniaturised piezoelectric transducers that are capable of exciting and receiving highly dispersive A0 Lamb wave mode at low frequencies. The scattering from transducer array has been found to have a small effect on the thickness reconstruction. The efficiency and the accuracy of the new system have been demonstrated through continuous forced corrosion experiments. The FWI reconstructed thicknesses show good agreement with analytical predictions obtained by Faraday’s law and laser measurements, and more importantly, the thickness images closely resemble the actual corrosion sites.

[1]  Peter Cawley,et al.  Experimental and numerical evaluation of electromagnetic acoustic transducer performance on steel materials , 2012 .

[2]  Jian Cai,et al.  Research on a Lamb Wave and Particle Filter-Based On-Line Crack Propagation Prognosis Method , 2016, Sensors.

[3]  I. Štekl,et al.  Accurate viscoelastic modeling by frequency‐domain finite differences using rotated operators , 1998 .

[4]  C. Bunks,et al.  Multiscale seismic waveform inversion , 1995 .

[5]  Bo Sun,et al.  Lamb-Wave-Based Tomographic Imaging Techniques for Hole-Edge Corrosion Monitoring in Plate Structures , 2016, Materials.

[6]  Glenn I. Roisman,et al.  I. Introduction. , 2014, Monographs of the Society for Research in Child Development.

[7]  Joseph L. Rose,et al.  Guided Wave Tomography on an Aircraft Wing with Leave in Place Sensors , 2005 .

[8]  C. Shin,et al.  An optimal 9-point, finite-difference, frequency-space, 2-D scalar wave extrapolator , 1996 .

[9]  Pierre R. Roberge,et al.  Corrosion Inspection and Monitoring , 2007 .

[10]  Matthias Seher,et al.  Experimental Studies of the Inspection of Areas With Restricted Access Using A0 Lamb Wave Tomography , 2016, IEEE Transactions on Ultrasonics, Ferroelectrics, and Frequency Control.

[11]  Peter Huthwaite,et al.  Evaluation of inversion approaches for guided wave thickness mapping , 2014, Proceedings of the Royal Society A: Mathematical, Physical and Engineering Sciences.

[12]  P. Nagy,et al.  Ultrasonic Computerized Tomography for Continuous Monitoring of Corrosion and Erosion Damage in Pipelines , 2015 .

[13]  Peter B. Nagy,et al.  Corrosion and Erosion Monitoring of Pipes by an Ultrasonic Guided Wave Method , 2007 .

[14]  Belkheir Hammouti,et al.  Corrosion control of carbon steel in phosphoric acid by purpald – Weight loss, electrochemical and XPS studies , 2012 .

[15]  Jean-Yves Fourniols,et al.  Toward Smart Aerospace Structures: Design of a Piezoelectric Sensor and Its Analog Interface for Flaw Detection , 2014, Sensors.

[16]  K. Marfurt.  Accuracy of finite-difference and finite-element modeling of the scalar and elastic wave equations , 1984 .

[17]  Frederic Cegla,et al.  High accuracy ultrasonic monitoring of electrochemical processes , 2017 .

[18]  R. Pratt,et al.  INVERSE THEORY APPLIED TO MULTI‐SOURCE CROSS‐HOLE TOMOGRAPHY.: PART 1: ACOUSTIC WAVE‐EQUATION METHOD1 , 1990 .

[19]  P Cawley,et al.  High-temperature (>500°c) wall thickness monitoring using dry-coupled ultrasonic waveguide transducers , 2011, IEEE Transactions on Ultrasonics, Ferroelectrics and Frequency Control.

[20]  F. Cegla,et al.  Wireless Ultrasonic Thickness Monitoring at Elevated Temperatures , 2011 .

[21]  F. Simonetti,et al.  High-resolution guided wave tomography , 2013 .

[22]  P Huthwaite,et al.  Guided wave tomography with an improved scattering model , 2016, Proceedings of the Royal Society A: Mathematical, Physical and Engineering Sciences.

[23]  Steven E. Owens,et al.  Ultrasonic Lamb wave tomography in structural health monitoring , 2011 .

[24]  Jesus Porcayo-Calderon,et al.  Study of molten salt corrosion of HK-40m alloy applying linear polarization resistance and conventional weight loss techniques , 2004 .

[25]  S. Operto,et al.  Mixed‐grid and staggered‐grid finite‐difference methods for frequency‐domain acoustic wave modelling , 2004 .

[26]  Joseph L. Rose,et al.  Ultrasonic Guided Wave Imaging Techniques in Structural Health Monitoring , 2010 .

[27]  C. B. Scruby,et al.  Non-contact ultrasonic measurements on steel at elevated temperatures , 1993 .

[28]  N. Duric,et al.  On the spatial sampling of wave fields with circular ring apertures , 2007 .

[29]  Zheng Fan,et al.  Guided Wave Tomography Based on Full Waveform Inversion , 2016, IEEE Transactions on Ultrasonics, Ferroelectrics, and Frequency Control.

[30]  Jean Virieux,et al.  Quantitative imaging of complex structures from dense wide‐aperture seismic data by multiscale traveltime and waveform inversions: a case study , 2004 .

[31]  R. Gerhard Pratt,et al.  Efficient waveform inversion and imaging: A strategy for selecting temporal frequencies , 2004 .

[32]  Changsoo Shin,et al.  Efficient calculation of a partial-derivative wavefield using reciprocity for seismic imaging and inversion , 2001 .

[33]  P. Cawley,et al.  Development of a low-frequency high purity A0 mode transducer for SHM applications , 2009, IEEE Transactions on Ultrasonics, Ferroelectrics and Frequency Control.

[34]  Peter Cawley,et al.  Potential drop mapping for the monitoring of corrosion or erosion , 2010 .

[35]  Peter Cawley,et al.  Guided wave diffraction tomography within the born approximation , 2010, IEEE Transactions on Ultrasonics, Ferroelectrics and Frequency Control.

[36]  Gabriele Rocchini,et al.  Corrosion rate monitoring by the linear polarization method , 1993 .

[37]  B. B. Bauer,et al.  Fundamentals of acoustics , 1963 .

[38]  R. G. Pratt,et al.  Two‐dimensional velocity models from wide‐angle seismic data by wavefield inversion , 1996 .

[39]  Denes Vigh,et al.  Developing Earth models with full waveform inversion , 2009 .

[40]  Jay L. Fisher,et al.  Flaw depth sizing using guided waves , 2016 .

[41]  P.D. Wilcox,et al.  On the development and testing of a guided ultrasonic wave array for structural integrity monitoring , 2006, IEEE Transactions on Ultrasonics, Ferroelectrics and Frequency Control.

[42]  P. Wilcox,et al.  Evaluation of the damage detection capability of a sparse-array guided-wave SHM system applied to a complex structure under varying thermal conditions , 2009, IEEE Transactions on Ultrasonics, Ferroelectrics and Frequency Control.

[43]  Zheng Fan,et al.  Investigation of the reconstruction accuracy of guided wave tomography using full waveform inversion , 2017 .