In this study, a fatigue crack detection technique, which detects a fatigue crack without relying on any reference data obtained from the intact condition of a target structure, is developed using nonlinear ultrasonic modulation and applied to a real bridge structure. Using two wafer-type lead zirconate titanate (PZT) transducers, ultrasonic excitations at two distinctive frequencies are applied to a target inspection spot and the corresponding ultrasonic response is measured by another PZT transducer. Then, the nonlinear modulation components produced by a breathingcrack are extracted from the measured ultrasonic response, and a statistical classifier, which can determine if the nonlinear modulation components are statistically significant in comparison with the background noise level, is proposed. The effectiveness of the proposed fatigue crack detection technique is experimentally validated using the data obtained from aluminum plates and aircraft fitting-lug specimens under varying temperature and loading conditions, and through a field testing of Yeongjong Grand Bridge in South Korea. The uniqueness of this study lies in that (1) detection of a micro fatigue crack with less than 1 μm width and fatigue cracks in the range of 10-20 μm in width using nonlinear ultrasonic modulation, (2) automated detection of fatigue crack formation without using reference data obtained from an intact condition, (3) reliable and robust diagnosis under varying temperature and loading conditions, (4) application of a local fatigue crack detection technique to online monitoring of a real bridge.
A piezoelectric fiber patch (PFP) is a transducer type that is suitable for guided-wave-based structural health monitoring (SHM) due to its light, thin, and flexible characteristics. In our previous work, a PFP-based transducer design for selective excitation of the zero-order shear horizontal wave mode (SH0) was introduced (shear horizontal PFP (SHPFP)). In this work, two modified SH0 wave PFP transducer designs are proposed: the rounded corner design and the dual design. The degree of improvement is determined by a numerical simulation and the dual design—the design with the most promise—is experimentally realized. Laser Vibrometry measured the generated wave field, confirming the results from the simulation. The new designs can generate an almost pure SH0 wave. The dual design has a very strong directivity that is useful for several guided-wave-based SHM applications. The conclusions on the design’s properties as a transmitter are also valid for its properties as a sensor due to the reciprocity of piezoelectric transducers.
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