In Situ Fatigue Damage Monitoring by Means of Nonlinear Ultrasonic Measurements

In the present work, the results of acoustic nonlinear response of ultrasonic wave propagation when monitoring the progress of damage induced by fatigue on notched C45 carbon steel specimens have been reported. Two ultrasound probes were fixed to the specimens during the tests. The input signal was sinusoidal type, while the corresponding ultrasound response signal was acquired and recorded at each stage of the test by means of a digital oscilloscope. A nonlinear frequency study was performed on the acquired data to evaluate the change in the second- and third-order nonlinearity coefficients of beta 1 and beta 2, respectively, on the tested specimens. Ultrasonic results were correlated to plastic strain at the notch tip in the initial phases of fatigue and stiffness degradation. The results showed a significant increase in second-order nonlinearity beta 1 in the early stages of fatigue life. Subsequently, starting from about 30-40% of the fatigue life, the nonlinearity of beta 1 increases. Before final failure, from 80 to 85% of fatigue life, the second-order nonlinearity further increases in the crack propagation stages. The nonlinear parameter of the third-order beta 2 was less sensitive to damage than the parameter beta 1, showing a rapid increase only starting from approximately 80 to 85% of the fatigue life. The proposed method proved to be valid for detective damage induced by fatigue and to predict the lifetime of metal materials.