Numerical predictions and experiments for optimizing hidden corrosion detection in aircraft structures using Lamb modes

To increase the sensitivity of Lamb waves to hidden corrosion in aircraft structures, a preliminary step is to understand the phenomena governing this interaction. A hybrid model combining a finite element approach and a modal decomposition method is used to investigate the interaction of Lamb modes with corrosion pits. The finite element mesh is used to describe the region surrounding the corrosion pits while the modal decomposition method permits to determine the waves reflected and transmitted by the damaged area. Simulations make easier the interpretation of some parts of the measured waveform corresponding to superposition of waves diffracted by the corroded area. Numerical results permit to extract significant information from the transmitted waveform and thus to optimize the signal processing for the detection of corrosion at an early stage. Now, we are able to detect corrosion pits down to 80-μm depth distributed randomly on a square centimeter of an aluminum plate. Moreover, thickness variations present on aircraft structures can be discriminated from a slightly corroded area. Finally, using this experimental setup, aircraft structures have been tested.