Advances in ultrasound inspection for complex geometries and materials

Abstract

The inspection of components with complex geometry or microstructure poses a significant challenge, particularly for the detection of volumetric defects. These limitations often necessitate destructive sampling inspections, leading to the generation of defective parts and, in many cases, considerable loss of time and resources.

This study presents an innovative non-destructive testing approach that relies on ultrasound imaging techniques (UT-IMAGING). These methods provide clear advantages over conventional ultrasound (UT) techniques, which frequently yield inadequate signals when inspecting intricate components. Such limitations mainly arise because traditional UT systems are not designed for curved surfaces or materials exhibiting anisotropic behavior.

UT-IMAGING improves the interpretation of signals generated by advanced ultrasonic transducers. The proposed methodology integrates dedicated simulation models to support inspection design and advanced post-processing algorithms capable of accurately reconstructing the ultrasound images. The approach has been validated through simulation in two industrially relevant scenarios: complex welds in the automotive industry and single-crystal materials with homogeneous anisotropy. The results indicate that UT-IMAGING, enhanced by computational modeling and advanced signal processing, offers a promising pathway and may serve as the basis for future inspection strategies in industries where ensuring component quality is critical.