Sub-wavelength resolution in air-coupled ultrasound images of spot welds

Resistance spot welds joining steel sheets were examined using air-coupled ultrasound at 1 MHz. Transmission C-scan images were obtained using two axially aligned transducers, with each focused on its adjacent surface of the specimen. Because of the enormous impedance mismatch between air and steel, the transmitted signal was exceedingly weak, requiring several hours to collect an image. Although the air-coupled images resembled the weld shapes as determined by an independent technique, surface topography introduced considerable image distortion. The smearing of the images was substantially less than the 5.9-mm wavelength in steel, with the steepness of the transition between welded and unwelded areas indicating a transverse resolution about 1 mm. Similarities to near-field imaging are mentioned as a possible explanation for the observed sub-wavelength resolution.