Development of an Ultrasonic System for the Reliable Detection and Sizing of Sustained Load Cracks in Aluminum Cylinders

The feasiblity of developing a PC based, pulsed ultrasonic test system for the economical and reliable testing of aluminum cylinders for sustained load cracking is addressed. A system consisting of a host PC, ultrasonic pulser/receiver and data acquisition hardware, control and analysis software, and transducer fixture for accurate positioning is proposed. In addition to the system development, specific testing protocol will be established which will aid in identifying specific areas which Phase II development would focus on. Specific problems which will be addressed include the establishment of test specifics to assure repeatable, 100% crack detection of the suspect area, accurate defect sizing techniques to be used in establishing accept/reject limits and lastly, a controllable inspection process which will ultimately lend itself to widescale commercialization. All development will be performed with the ultimate outcome being that of a rapid, inexpensive, highly reliable test, suitable for wide scale use at cylinder re-test facilities throughout the United States (Phase III).