A system model for ultrasonic NDT based on the Physical Theory of Diffraction (PTD)

•A 3D PTD-based ultrasonic system model for crack-like flaws is proposed.•It is a unified model for simulating both reflection and edge diffraction.•Numerical validation has been successful for both P and S waves.•The PTD model has also been extended to apply near critical observation angles.•Experimental validation has proved successful too in numerous 2D or 3D NDT configurations.

Simulation of ultrasonic Non Destructive Testing (NDT) is helpful for evaluating performances of inspection techniques and requires the modelling of waves scattered by defects. Two classical flaw scattering models have been previously usually employed and evaluated to deal with inspection of planar defects, the Kirchhoff approximation (KA) for simulating reflection and the Geometrical Theory of Diffraction (GTD) for simulating diffraction. Combining them so as to retain advantages of both, the Physical Theory of Diffraction (PTD) initially developed in electromagnetism has been recently extended to elastodynamics. In this paper a PTD-based system model is proposed for simulating the ultrasonic response of crack-like defects. It is also extended to provide good description of regions surrounding critical rays where the shear diffracted waves and head waves interfere. Both numerical and experimental validation of the PTD model is carried out in various practical NDT configurations, such as pulse echo and Time of Flight Diffraction (TOFD), involving both crack tip and corner echoes. Numerical validation involves comparison of this model with KA and GTD as well as the Finite-Element Method (FEM).