The aim of this work was to provide further confirmation of the possible use of non-linear ultrasonic techniques for detecting the cracking due to corrosion of steel reinforcements in concrete. To this end accelerated steel corrosion tests have been conducted on model reinforced cement mortar specimens, while monitoring the appearance and width evolution of visible surface cracks, and performing non-linear ultrasonic measurements based on the phenomena of harmonic distortion and intermodulation. A new parameter, based on the difference between the amplitude of the fundamental frequency and the sum of the amplitudes of all the first-order and second-order intermodulation products, has been proposed in this work. The results confirm that the appearance of visible surface micro-cracks are preceded and accompanied by the observation of strong non-linear features in the received signal. Furthermore, the new parameter proposed in this work is as efficient as the relative non-linearity parameters, classically used in harmonic distortion non-linear ultrasonic studies, for detecting the non-linear features associated with the critical events of the cracking of cement mortar due to embedded steel corrosion. A hypothesis has been developed considering the possible effect of the filling of the void space by liquid containing rust products after the formation of new cracks or the enlargement of its width. This filling process, which might be particularly enhanced by net convective transport of liquid, would explain the evolution of the values of all the parameters used for putting in evidence the non-linear elastic features after the critical events of the cracking process.
