Journal Articles

This article presents a systematic investigation of power and energy transduction in piezoelectric wafer-active sensors (PWAS) for structural health monitoring (SHM). After a literature review of the state-of-the-art, we developed a predictive modeling of the multi-physics power and energy transduction between structurally guided waves and PWAS in closed-form analytical expressions. The model assumptions include: (a) one-dimensional axial and flexural wave propagations; (b) ideal bonding (pin-force) connection between PWAS and structure; and (c) ideal excitation source at the transmitter PWAS and fully resistive external load at the receiver PWAS. Both wave propagation method for an infinite beam and normal mode expansion method for a finite beam were considered. Frequency response functions were developed for voltage, current, complex power, active power, etc. The power and energy analysis for single PWAS transmitter, single PWAS receiver and a complete PWAS pitch-catch setup were considered. The numerical simulation and graphical charts show the trends in the power and energy flow behavior of PWAS for SHM. The peaks and valleys of power can be exploited for optimum design for PWAS SHM applications.

Monitoring of fatigue cracking in steel bridges is of high interest to many bridge owners and agencies. Due to the variety of deterioration sources and locations of bridge defects, there is currently no single method that can detect and address the potential sources globally. In this paper, we presented a dual mode sensing methodology integrating acoustic emission and ultrasonic wave inspection based on the use of low-profile piezoelectric wafer active sensors (PWAS). After introducing the research background and piezoelectric sensing principles, PWAS crack detection in passive acoustic emission mode is first presented. Their acoustic emission detection capability has been validated through both static and compact tension fatigue tests. With the use of coaxial cable wiring, PWAS AE signal quality has been improved. The active ultrasonic inspection is conducted by the damage index and wave imaging approach. The results in the paper show that such an integration of passive acoustic emission detection with active ultrasonic sensing is a technological leap forward from the current practice of periodic and subjective visual inspection and bridge management based primarily on history of past performance.

A time–frequency analysis-based signal processing study for detecting active corrosion in aluminum plate-like structure utilizing the broadband piezoelectric wafer active sensors is presented in this article. Tests were conducted on an aluminum plate with a network of sensors installed on one side of the plate for Lamb wave generation and reception. The corrosion was emulated as material loss of an area of 50 × 38 mm2 on the opposite side of the plate. The corroded area resulted in a thickness loss on the plate and a change in wave propagation as well. The experimental data were first evaluated by a statistical damage index (DI) based on root mean square values and then the Cohen’s class motivated cross-time–frequency analysis. The cross-time–frequency analysis was found more reliable and precise for detecting the corrosion progression when compared to the DI method. Not only can the proposed metric correctly evaluate the phase difference of specific frequency and time, it also carries useful information of phase difference, which is strongly correlated to the physics of corrosion detection using Lamb waves. Novel aspects of this study include a sensing approach that can sense corrosion damage on both external and internal surfaces of a given structure, the employment of effective tuning in corrosion detection, and using cross-time–frequency analysis to quantitatively evaluate thickness loss. Though the corrosion studied herein is an idealized and simplified situation, the subject work on phase difference and cross-time–frequency analysis is useful first-step effort and opens a new way to perform Lamb wave-based corrosion detection. The results presented in this article combine easy-to-examine corrosion assumptions together with low-frequency antisymmetric Lamb wave analysis to provide a stepping stone for more complicated analysis needed for further real life corrosion assessment.

This paper discusses the topic of how the integrity of safety-critical structural composites can be enhanced by the use of structural health monitoring (SHM) techniques. The paper starts with a presentation of how the certification of flight-critical composite structures can be achieved within the framework of civil aviation safety authority requirements. Typical composites damage mechanisms, which make this process substantially different from that for metallic materials are discussed. The opportunities presented by the use of SHM techniques in future civil aircraft developments are explained. The paper then focuses on active SHM with piezoelectric wafer active sensors (PWAS). After reviewing the PWAS-based SHM options, the paper follows with a discussion of the specifics of guided wave propagation in composites and PWAS-tuning effects. The paper presents a number of experimental results for damage detection in simple flat unidirectional and quasi-isotropic composite specimens. Calibrated through holes of increasing diameter and impact damage of various energies and velocities are considered. The paper ends with conclusions and suggestions for further work.

The modeling of the interaction between piezoelectric wafer active sensors (PWAS) and structural waves and vibration is addressed. Three main issues are discussed: (a) modeling of pitch-catch ultrasonic waves between a PWAS transmitter and a PWAS receiver by comparison between exact Lamb wave solutions and various finite element method (FEM) results; (b) analytical modeling of the power and energy transduction between PWAS and ultrasonic guided waves highlighting the tuning opportunities between PWAS and the waves; (c) the use of the transfer matrix method to model the electromechanical (E/M) impedance method for direct reading of high-frequency local structural vibration and comparison with FEM results. The paper ends with a summary and conclusions followed by recommendations for further work.

An experimental evaluation of the structural health monitoring capability of piezoelectric wafer active sensors on composite structures at cryogenic temperatures is presented. The piezoelectric wafer active sensor–based electromechanical impedance and the pitch–catch methods were first qualified for cryogenic temperatures using piezoelectric wafer active sensor–instrumented composite specimens dipped in liquid N2. Subsequently, damage detection experiments were performed on laboratory-scale composite specimens with (a) impact damage and (b) built-in Teflon patches simulating in service delaminations. Finally, a comprehensive damage detection test was performed on a full-scale specimen subjected to pressure and cryogenic temperature cycles. Based on these tests, we conclude that piezoelectric wafer active sensor–based structural health monitoring methods show promise for damage detection in composite materials even in extreme cryogenic conditions. Recommendations for further work are also included.

The advancement of composite materials in aircraft structures has led to an increased need for effective structural health monitoring technologies that are able to detect and assess damage present in composite structures. The study presented in this article is interested in understanding self-sensing piezoelectric wafer sensors to conduct electromechanical impedance spectroscopy in glass fiber reinforced polymer composite to perform structural health monitoring. For this objective, multi-physics-based finite element method is used to model the electromechanical behavior of a free piezoelectric wafer active sensor and its interaction with the host structure on which it is bonded. The multi-physics-based modeling permits the input and output variables to be expressed directly in electric terms, while the two-way electromechanical conversion is done internally in the multi-physics-based finite element method formulation. The impedance responses are also studied in conditions when the sensor bonding layer is subject to degradation and when the sensor itself is subjected to breakage, respectively. To reach the goal of using the electromechanical impedance spectroscopy approach to detect damage, several damage models are generated on simplified orthotropic structure and laminated glass fiber reinforced polymer structures. The effects of the modeling are carefully studied through experimental validation. A good match has been observed for low and high frequencies.

This paper addresses some unresolved predictive modeling issues related to the use of piezoelectric-wafer active sensors for ultrasonic structural health monitoring. An exact model for the shear-lag transfer between the piezoelectric-wafer active sensor transducer and the structure in the presence of N generic guided wave modes is derived from first principles using the normal-mode expansion formulation. The resulting integral differential equation is solved using the variational iteration approach. The resulting solution is used to derive an improved model for the tuning between piezoelectric-wafer active sensor transducers and the multimodal guided waves used in ultrasonic structural-health-monitoring applications. The numerical predictions generated by the improved tuning model are compared with experimental results obtained through pitch catch experiments between two 7 mm piezoelectric-wafer active sensor transducers placed on a 1-mm 2024-T3 aluminum plate. The 10-700 kHz frequency range was explored. It was concluded that the improved model using the exact shear-lag solution matches much better the experimental results than previous models. Further theoretical and experimental work is warranted as a follow-up on the work reported in this paper to study the accuracy and convergence properties of the solution, to explore experimental comparison beyond the A1-mode cutoff frequency, and to extend the approach to layered structures and composite materials.

Recent advancements in sensors and information technologies have resulted in new methods for structural health monitoring (SHM) of the performance and deterioration of structures. The enabling element is the piezoelectric wafer active sensor (PWAS). This paper presents an introduction to PWAS transducers and their applications in Lamb wave-based SHM. We begin by reviewing the fundamentals of piezoelectric intelligent materials. Then, the mechanism of using PWAS transducers as Lamb wave transmitters and receivers is presented. PWAS interact with the host structure through the shear-lag model. Lamb wave mode tuning can be achieved by judicious combination of PWAS dimensions, frequency value, and Lamb mode characteristics. Finally, use of PWAS Lamb wave SHM for damage detection on plate-like aluminum structures is addressed. Examples of using PWAS phased array scanning, quantitative crack detection with array imaging, and quantitative corrosion detection are given.