Ultrasonic inspection of curved structures with a hemispherical-omnidirectional ultrasonic probe via linear scan SAFT imaging

A reliable non-destructive testing technique that enables effective detection and quantification of defects within safety-critical curved structures is highly demanded both in manufacture and service. Conventional Ultrasonic Testing (UT) methods usually adopt planar ultrasonic probes and it is preferable to adjust the probe axis direction perpendicular to the curved surface, because both the transmitting and receiving sensitivities in the probe axis direction are the highest. This paper proposes a new UT method using a hemispherical-omnidirectional ultrasonic probe. This probe has an omnidirectional directivity pattern and can cover curved surfaces with normal incident ultrasounds at different scan positions without the necessity of adjusting the probe attitude and position to follow the curved surface profiles. A surface reconstruction algorithm is firstly proposed to estimate curved surface profiles, which is based on a fast-imaging algorithm for ultra-wideband radar called the Shape Estimation Algorithm based on the Boundary scattering transform and Extraction of Directly scattered waves (SEABED). This method only uses surface reflection echoes, and thus can inspect curved structures without knowing the surface profiles a prior. Further, the Synthetic Aperture Focusing Technique (SAFT) is implemented to generate a focused image of internal defects by performing delay-and-sum beamforming on defect echoes based on the reconstructed surface profile. The proposed UT method is eventually experimentally verified on a curved plexiglass specimen with 29.4 mm surface curvature radius containing three empty set 3.5 mm Side Drilled Holes (SDHs) at different depths. Results show that compared with the planar ultrasonic probe, the reconstructed surface profile via SEABED is much wider and accurate with a relative error <= 0.47%. All SDHs are not only clearly positioned with relative errors <= 7.43%, but also can be accurately quantified from the curvature radius of SDH indications in the SAFT images with relative errors <= 8.60%. This work proves that the UT method based on the hemispherical-omnidirectional ultrasonic probe can emerge as a promising technique to inspect curved structures with high efficiency and accuracy, which has great potential in practical applications.