Nonlinear features of guided wave scattering from rivet hole nucleated fatigue cracks considering the rough contact surface condition

This article presents the investigation of nonlinear scattering features of guided waves from rivet hole nucleated fatigue cracks considering the rough contact surface condition. A small-size numerical model based on the local interaction simulation approach is developed, enabling the efficient analysis of the contact acoustic nonlinearity during the wave crack interactions. The study starts with an idealized breathing crack model possessing smooth, perfectly kissing contact surfaces. Then, the nature of rough crack surfaces is considered with randomly distributed initial openings and closures. Several distinctive aspects of the nonlinear scattering phenomenon are discussed: (1) the amplitude effect, which renders significantly different nonlinear response under various levels of excitation wave amplitudes; (2) the directivity and mode conversion features, which addresses the scattering direction dependence of the fundamental and superharmonic wave mode components; (3) the nonlinear resonance phenomenon, which maximizes the nonlinear response during the wave crack interactions at certain excitation frequency ranges. This study demonstrates that these nonlinear features are substantially influenced by the crack surface condition and differ much between an idealized breathing crack and a rough crack in most practical cases. Fatigue tests on a thin aluminum plate with a rivet hole is conducted to induce cracks in the specimen. An active sensor array surrounding the crack zone is implemented to generate and receive ultrasonic guided waves in various directions. Current work emphasizes on using a highly efficient numerical model to explain the nonlinear features of scattered waves from fatigue cracks considering the rough crack surface condition. These special features may provide insights and guidelines for nonlinear guided wave based nondestructive evaluation and structural health monitoring system design. The paper finishes with discussion, concluding remarks, and suggestions for future work.