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This research develops a robust experimental procedure to track the evolution of fatigue damage in a nickel-base superalloy with the acoustic nonlinearity parameter, β, and demonstrates its effectiveness by making repeatable measurements of β in multiple specimens, subjected to both high- and low-cycle fatigue. The measurement procedure developed in this research is robust in that it is based on conventional piezoelectric contact transducers, which are readily available off the shelf, and it offers the potential for field applications. In addition, the measurement procedure enables the user to isolate sample nonlinearity from measurement system nonlinearity. The experimental results show that there is a significant increase in β linked to the high plasticity of low-cycle fatigue, and illustrate how these nonlinear ultrasonic measurements quantitatively characterize the damage state of a specimen in the early stages of fatigue. The high-cycle fatigue results are less definitive (the increase in β is not as substantial) due to increased uncertainties involved in the high-cycle fatigue tests, but still show a clear relationship between β and remaining fatigue life. One application of the measured β versus fatigue-life data is to potentially serve as a master curve for life prediction based on nonlinear ultrasonic measurements.

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This paper presents a comprehensive review of the current state of knowledge of second harmonic generation (SHG) measurements, a subset of nonlinear ultrasonic nondestructive evaluation techniques. These SHG techniques exploit the material nonlinearity of metals in order to measure the acoustic nonlinearity parameter, β. In these measurements, a second harmonic wave is generated from a propagating monochromatic elastic wave, due to the anharmonicity of the crystal lattice, as well as the presence of microstructural features such as dislocations and precipitates. This article provides a summary of models that relate the different microstructural contributions to β, and provides details of the different SHG measurement and analysis techniques available, focusing on longitudinal and Rayleigh wave methods. The main focus of this paper is a critical review of the literature that utilizes these SHG methods for the nondestructive evaluation of plasticity, fatigue, thermal aging, creep, and radiation damage in metals.

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