Comparison of Reflection Mode

Acoustography and C-scan Ultrasonic

Techniques for the Single Sided
Inspection of Aerospace Materials
R.E. Martin
Cleveland State University/NASA GRC
A. Mandlik, W. Popek, M. Sonpatki, J. Sandhu
Santec Systems Inc.
D. Roth
NASA Glenn Research Center
C. Pergantis
US Army Research Laboratory
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 Outline

 Introduction
 Overview of Acoustography
 Single Sided Reflection Mode
Acoustography Approach
 Experimental Setup
 Results
 Conclusions
 Future Directions

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 Introduction
 Many structures and components in use today
require NDE inspection where access is limited
to one side
 These inspections are typically performed using
point by point or scanning techniques
 Inspections of this type can be time consuming
and typically require skilled operators for
testing and data interpretation
 Ideally, the development of a large area
inspection device would reduce these demands
 Ultrasonic Inspections using single sided
acoustography are being considered as a
possible solution
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 Acoustography

What is Acoustography?

It is the Ultrasound analog of:

• Real-Time Radiography
• Digital Photography

Large area excitation and detection enable:

• Full field image formation
• Near real-time results

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 Acoustography
Basic Principle – Image Formation

• Analogous to x-ray
imaging

• AO Sensor allows near

real-time visualization
of ultrasound

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 Acoustography
Basic Principle – AO Sensor

• AO sensor contains a
layer of proprietary LC
material
• LC molecules reorient
when exposed to
ultrasound
• Ultrasonically exposed
area becomes birefringent
showing contrast change
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 Acoustography Process
Composite Sample AO Inspection
5 cm
 Acoustography
– Converts UT directly into
visual image in near real-
time 5 cm

– Results compare well with

through transmission C-scan
Single Flaw

Conventional C-scan Acoustography

(3.3 MHz) 7
(5 MHz)
 Acoustography
Single Sided Reflection Mode
 Reflection mode acoustography enables single sided
inspection.
 Ultrasound passes through AO sensor and interacts with
material under test.
 Images are captured using a CCD camera and frame grabber.
 Differential response from AO detector at flaw locations
provides image contrast

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 Experimental Procedure
 Single sided acoustography tests were
conducted on PMC materials subjected
to impact damage
 Two reflection mode systems were
used, a laboratory system and a
prototype handheld system
 Pulse-Echo C-scans were performed on
the same samples and used as a basis
for comparison

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 Material

 Polymer Matrix Composite (PMC)

– AS4/3501, +/- 45° Lay-up, 4” x 3”
– Impact damaged Samples:
 Sample #1: 15 Joule, 32 plies
 Sample #2: 5 joules, 16 plies (just barely visible)

 Samples were air-backed to simulate

real inspection situation

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 Experimental Setup
(Laboratory System)
 Sample placed in water tank (air-backed)
 3” x 3” AO sensor placed on top of sample
 2.5”x2.5” 3.3MHz transducer was placed above
the AO sensor and powered for 10 seconds
 Images were acquired using a CCD camera
under polarized light

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 Experimental Setup
(Prototype System)
 Handheld system uses smaller
(1”x1”) AO sensor for portability
 AO sensor coupled to sample
using ultrasonic gel
 Sound source coupled using
distilled water in housing
 3.3MHz sound source used
 All components (sound source,
camera, AO sensor and light
contained in one unit)

First Prototype System

(1” X 1” AO Sensor)

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 Experimental Setup
(Pulse Echo C-scan)

 Commercial ultrasonic
scanner
 Water immersion with
air-backed sample
 3.5MHz focused
transducer closely
matches acoustography
frequency

 Images display peak

Ultrasonic C-Scan System amplitude of back wall
echo

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 Results
Impact Damaged PMC – Sample #1

Pulse-Echo
C-Scan

Reflection Mode Acoustography Reflection Mode Acoustography

Imaged Using Lab System Imaged Using Lab System
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(Approximate Area Shown by Black (Approximate Area Shown by Red Square)
 Results
Impact Damaged PMC – Sample #2

Pulse-Echo
C-Scan

Reflection Mode Acoustography Reflection Mode Acoustography

Image Using Prototype System Image Using Prototype System
(Approximate Area Shown by Black Square) (Approximate Area Shown by Red Square)
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 Results
PMC Honeycomb Sample

Reflection Reflection mode

Pulse-echo C- mode acoustography
Scan acoustography image using
image using Prototype
Prototype system
system (good (Crushed core
area) area)

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 Conclusions
 Both laboratory and prototype reflection mode
acoustography systems are able to image
impact damage in PMC panels

 Reflection mode acoustography was able to

image honeycomb structure and provided
indications related to crushed core region

 Both systems demonstrated large area

ultrasonic imaging capability using a single
sided technique

 Acoustographic inspection requires minimal

setup and inspection time compared to C-scan

 Results correlate well with ultrasonic C-scan at

a similar frequency 17
 Future Directions
 Refine prototype system for improved
image quality
– Investigate interface materials and matching
layers
– Reduce noise associated with ultrasonic source
interacting with AO sensor
 Develop and apply image processing
tools for improved defect detection
capabilities
– Tools for use in through transmission
acoustography have been developed and will
be tailored for reflection mode use

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