ARTICLE IN PRESS

Mechanical Systems
and
Signal Processing
Mechanical Systems and Signal Processing 22 (2008) 1327–1335
www.elsevier.com/locate/jnlabr/ymssp

Damage detection in composite plates with

embedded PZT transducers
P. Kudelaa,,1, W. Ostachowicza,b, A. Żaka
a
Institute of Fluid Flow Machinery, Polish Academy of Sciences, ul. Fiszera 14, 80 952 Gdansk, Poland
b
Faculty of Navigation, Gdynia Maritime University, Al. Jana Pawa II 3, 81 345 Gdynia, Poland
Received 5 January 2007; received in revised form 16 July 2007; accepted 17 July 2007
Available online 2 August 2007

Abstract

This paper presents a concept of a structural health monitoring system based on PZT transducers. Taking advantage of
spectral element method simulations of A0 mode of the Lamb waves propagating in a multilayer composite plate have
been carried out. Based on obtained signals for a clock-like configuration of sensors, a damage detection algorithm has
been proposed. The results for the proposed algorithm have been presented in the form of damage maps. It can be
concluded that the clock-like sensor configuration is suitable for embedding in composite plates because information about
wave velocities at each angle can be included.
r 2007 Elsevier Ltd. All rights reserved.

Keywords: Crack detection; Signal processing; Composite plate

1. Introduction

As a human body, structures deteriorate or are damaged in a long-term use. The damage can be generated
by initial defects, fatigue, overloads, and impacts. In composite structures, the different damage modes
expected are: delamination, fibre breakage and matrix cracking. Damage and deterioration of structures
appear as a significant problem because they often cause catastrophic accidents. However, unlike a human
body, the health of structures cannot be self recovered. Therefore, periodic inspections are essential to ensure
the safe operation of structures [1].
Traditional nondestructive evaluation techniques such as: ultrasonic scan, eddy current method,
X radiography, acoustic emission and passive thermography are difficult to use in operation due to the size
and weight of necessary devices. Moreover, operation must be interrupted, parts must be disassembled and re-
assembled for inspection, which is complex, expensive and time consuming. In opposite, a structural health
monitoring system is an attractive approach to solve problems that occur in degraded structures. Damage and
intensity of degradation are monitored in real time providing useful information for predicting the service life.
Such a system can improve not only safety and reliability but also can reduce maintenance costs.

Corresponding author.
E-mail addresses: pk@imp.gda.pl (P. Kudela), wieslaw@imp.gda.pl (W. Ostachowicz), arek@imp.gda.pl (A. Żak).
1
Supported by the Polish Ministry of Education and Science (Proj. No. N501 001 31/0103).

0888-3270/$ - see front matter r 2007 Elsevier Ltd. All rights reserved.
doi:10.1016/j.ymssp.2007.07.008
 ARTICLE IN PRESS
1328 P. Kudela et al. / Mechanical Systems and Signal Processing 22 (2008) 1327–1335

Fig. 1. Configuration of sensors: (a) a distributed sensor array, and (b) a clock-like sensor array.

The most popular sensors suitable for embedding in structures are fibre-optic sensors and piezoelectric
sensors. In the first case, sensing area is focused around fibres and the cost of a complete system depends on
the type of sensors and configuration of distributing and multiplexing techniques. In the second case, the
sensing area is reasonably, sensors can be placed in a network configuration (Fig. 1a) or connected in a small
circular group working similar to radar devices (Fig. 1b). Piezoelectric sensing systems are cheaper than the
systems based on fibre-optic sensors and are the subject of this paper.

2. Lamb wave modelling

Piezoelectric sensors use diagnostic signals that are generated by impact or actuators. Input signals usually
excite Lamb waves. In practical application only input signals that excite fundamental modes of Lamb waves
(A0 and S0) are considered, in order to simplify interpretation of signal responses. In this case a wave
dispersion appears as an important problem. That situation requires to chose an optimal operation point
corresponding to an excitation frequency. The most suitable cycle number and frequency for a Lamb mode
can be determined by the minimum resolvable distance (MRD) approach [2]:
   
V0 1 1
MRD ¼ L  þ T in , (1)
d V min V max
where L and d are the wave propagation distance and plate thickness, V 0 , V min , V max are the group velocity at
the central frequency of the input wave-packet, minimum and maximum velocities in the wave packet to travel
through the distance of L, while T in is the duration of the input signal. It has been found that the smaller a
MRD value the better the resolution and the more suitable the current frequency and cycle number. Modes S0
and A0 are usually observed to have very low MRD values.
An effective development of damage detection systems which utilize guided waves must be supported by
numerical simulations. Wave propagation and scattering that appears in composite plates can be modelled by
taking advantage of spectral element method [3]. Spectral elements are versatile and can be applied to domains
of complex boundaries. Moreover, selection of suitable base functions and numerical integration points enable
equations uncoupling and crucial reduction of calculation time. Also convergence is very fast comparing with
the classical FEM.

3. Numerical calculations

3.1. Influence of composite material parameters on wave propagation

Parameters of composite materials strongly influence on the velocity of propagating waves. Waves in
composite plates propagate in each direction with different velocities. That can be plotted in the polar
coordinates as presented in Fig. 2. It can be seen that numerical model gives little slower wave front than the
wave front calculated using a simply analytical procedure given in [4].
Also the shape of the wave front changes with the frequency. For this reason a right choice of an optimal
excitation frequency should minimize dispersion (MRD value) and should give the most circular wave front.
Fortunately, the frequency range which gives a flat group velocity curve (Fig. 3) gives the most circular wave
 ARTICLE IN PRESS
P. Kudela et al. / Mechanical Systems and Signal Processing 22 (2008) 1327–1335 1329

90 1500
120 60 100 kHz
30 kHz
1000
20 kHz
150 s08
100 kHz simul.
500

180 0

210 330

240 300
270

Fig. 2. Group velocity surfaces calculated analytically compared with velocities estimated from a simulation (cross markers) by spectral
element method.

5
cω
cα
4 cβ
Group velocity [km/s]

×
1
105.7 kHz

~343 kHz

0
0 100 200 300 400 500 600
Frequency [kHz]

Fig. 3. Dispersion curves for a ½452 composite plate of 2 mm thick obtained from a mathematical model.

front. It should be noticed that dispersion curves presented in Fig. 3 are obtained from a mathematical model
of the composite plate based on Mindlin’s plate theory. This theory gives a good approximation of A0 mode
of the Lamb waves (cw curve in Fig. 3) only below cut off frequencies. A1 and A2 mode of the Lamb waves are
approximated very roughly (ca and cb curves in Fig. 3, which correspond to rotational degrees of freedom).
If a composite material contains more fibres then waves propagate at higher velocities. Also the shape of the
group velocity surface changes with the volume fraction of the fibres. The group velocity depends also on the
orientation angle of the reinforcing fibres. Theoretical and numerical calculations for a single layer graphite-
epoxy composite plate with a constant volume fraction of the fibres show that the front of the propagating
wave is preserved, while an ellipse shaped elongation is rotated according to the fibre orientation angle [4].

3.2. Multilayer composite plate with crack

A plate under consideration (Fig. 4) has the following dimensions: length 500 mm, width 500 mm, and
thickness 2 mm. The excitation source is a 105.7 kHz sinusoidal signal modulated by Hanning window of five
cycles. This frequency corresponds to the maximum group velocity of A0 mode of the Lamb waves (vide
Fig. 2). It is assumed that the plate consists of four graphite-epoxy layers. A volume fraction of the reinforcing
 ARTICLE IN PRESS
1330 P. Kudela et al. / Mechanical Systems and Signal Processing 22 (2008) 1327–1335

sensor array
12

9 3

6
100
500

200
200

500

Fig. 4. Geometry of a composite plate with two cracks.

fibres in each layer is 50%. The ply stacking sequence of the plate is ½452 . The total time of analysis has been
assumed 0.7 ms, which is enough for propagating wave to travel from excitation point to the boundaries of the
plate and back. The excitation point is located at the center of a clock-like array of sensors and the remaining
points in Fig. 4 indicate sensors.
Based on the assumptions described above, numerical simulations of A0 mode of the Lamb waves have
been carried out in the case of undamaged and damaged plate. This problem is solved by the use of spectral
element method. A grid of 30  30 100-node spectral plate elements has been used. It gives roughly 220 000
degrees of freedom and about seven nodes per wavelength. The total simulation time has been divided into
15 000 time steps. Such parameters assure stability of the method.
Two damage scenarios have been investigated. In the first case only crack no. 2 is present. In the second case
crack nos. 1 and 2 are present in the plate as presented in Fig. 4. Left tip of the crack no. 1 has coordinates
(300 mm, 83.3 mm) and length is 16.6 mm. Left tip of the crack no. 2 has coordinates (233 mm, 300 mm) and
the length 16.6 mm. The cracks have been introduced by separations appropriate element nodes.
Certain results of numerical simulations are presented in Fig. 5. Reflections from the cracks can be clearly
visible.

4. Damage detection algorithm

For the purpose of damage detection based on the signals registered by the considered clock-like manner
sensor array a simple detection algorithm has been proposed and developed, and founded on the ideas
presented in [5–7].
The proposed damage detection algorithm makes use of the assumption that the excitation signal and
signals reflected from damage have matching features. If this is true the idea is to search all signals registered
for signals reflected from damage and subsequently to compare the features of these signals with the features
of the excitation signal. The excitation signal has a finite length (Fig. 6) and thus can be thought of as
surrounded by a virtual time window. This time window can be arbitrarily placed on each of the registered
signals resulting in a certain time shift, which is equivalent to a distance required for the propagating signal to
travel from the excitation point (the central transmitter) to a point P of coordinates x and y (possible damage
location) and then back to an appropriate sensors. Based on the part of the registered signal matching the
extent of the time window a certain measure of the match between the signals can be built and associated with
 ARTICLE IN PRESS
P. Kudela et al. / Mechanical Systems and Signal Processing 22 (2008) 1327–1335 1331

Fig. 5. Snapshots of the propagating waves in a graphite-epoxy composite plate with one crack (left) and with two cracks (right) obtained
from simulation. (a,b) Time 0.07 ms; (c,d) time 0.12 ms; (e,f) time 0.16 ms; (g,h) time 0.21 ms.

the coordinates x and y. In the case when the registered signal, within the considered time window, is free of
the signal reflected from damage the value of this measure is very low and close to zero. On the other hand
when the registered signal carries on some information about the signal reflected from the damage the value of
the measure is much higher. A special damage influence map can be built by application of this procedure to
all points of the plate and by summation of the obtained results.
For the signal registered by the kth sensor it can be written that:
S^ T ¼ ST ðt0 ; t0 þ Dt Þ; S^ R;k ¼ S R;k ðt0 þ Dt; t0 þ Dt Þ; k ¼ 1; . . . ; 12, (2)
where t0 is the beginning time of the time window, Dt is the width of the time window and Dt is the signal time
shift (Fig. 6). The two time signals S^ T and S^ R;k obtained in this way have the same width Dt . The signal time
 ARTICLE IN PRESS
1332 P. Kudela et al. / Mechanical Systems and Signal Processing 22 (2008) 1327–1335

sensor array
12 V( )
9 3

d0P 6
dPk

P(x,y) P(x,y)

t t*

Fig. 6. The idea of a damage identification algorithm in a composite plate.

shift Dt may be expressed in terms of the distance between point P and the signal propagation group
velocity V as
qffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffi
pffiffiffiffiffiffiffiffiffiffiffiffiffiffiffi
d 0P d Pk 2
x þy 2 ðx  xk Þ2 þ ðy  yk Þ2
Dtðx; yÞ ¼ þ ¼ þ , (3)
V 0P V Pk V 0P V Pk
where d 0P and d Pk represent the distances between the central transmitter and point P and between point P
and kth sensor, respectively. It should be noticed that in composite materials the group velocity depends on
the direction of propagation (vide Fig. 2). For this reason the values of the group velocities V 0P and V Pk are
not equal and are different for each point P in opposite to an isotropic case. Based on the time signals S^ T and
S^ Rk the measure of the match between the two signals can be build and associated with the point P of
coordinates x and y as
Z t0 þDt
ek ðx; yÞ ¼ S^ T ðtÞ½F ðtÞGðx; yÞS^ Rk ðtÞ dt, (4)
t0

where F ðtÞ is a windowing function (such as Gauss, Hann, Hamming, etc.), while Gðx; yÞ is a function taking
into account the attenuation of the reflected signal amplitude:
Gðx; yÞ ¼ ea ðd 0P þd Pk Þ , (5)
where a is the attenuation coefficient. The total measure of the match between the signals obtained from all
receiving sensors can be build as follows:
XZ XX
E¼ ek ðx; yÞ dS  ek ðxi ; yj Þ,
k S k i;j

k ¼ 1; . . . ; 12; i ¼ 1; . . . ; N; j ¼ 1; . . . ; M, ð6Þ
where S is the surface of the plate and N and M represent the total number of nodes i and j located on the plate
surface.

4.1. Example of damage detection

The damage detection algorithm described in the previous section has been tested based on the results from
numerical simulations. The algorithm has been applied to signals registered by 12 sensors with random noise
 ARTICLE IN PRESS
P. Kudela et al. / Mechanical Systems and Signal Processing 22 (2008) 1327–1335 1333

up to 2% of the maximum amplitude of the signals. The plate has been divided into 200x200 nodes. The group
velocity of the propagation signal has been taken from the numerical simulations rather from the known
analytical formulas. The measure of the match between the two signals defined in Eq. (4) has been modified to
the form:

ek ðtj Þ ¼ jFðf c Þj  jDFT½F ðti ÞS^ Rk ðtj þ ði  1Þ dtÞj; i ¼ 1; . . . ; N w , (7)

where F is the linear interpolation of the amplitude corresponding to the carrier frequency f c of the excitation
signal S T , calculated using the signal registered by the kth sensor, the DFT denotes the discrete Fourier
transform, F is the Hanning window, dt is the sampling interval, and N w is the number of points in the virtual
window. Such definition causes that the damage detection algorithm can be classified as a time-frequency
method. Moreover, such a damage detection algorithm has excellent filtering properties. In all cases
investigated here the exact location of damage considered has been clearly indicated and marked for reference
purposes.
As a first damage influence maps have been built based on damage state signals (plate with cracks). It can be
seen that the reflections of the signal from the cracks (Figs. 7a and 8a) are obscured by the reflections from the
boundaries and the location of the cracks cannot be detected. However, boundary reflections can be removed
considering only the time of wave propagation from the central transmitter to the nearest boundary and back
to the nearest sensor. In such a case the damage influence map gives a clear indication of the location of the
cracks (Figs. 7b and 8b). In the case of two cracks a damage influence map clearly indicates the position of
crack no. 1, which is located closer to the centre of the sensor array and the value of the damage influ-
ence amplitude is high, while reflections from crack no. 2 cause that the second maximum of the damage

Fig. 7. Numerical results: damage influence maps for a plate with one crack (white mark). (a) Signals without a baseline; (b) Signals
without a baseline and with boundary reflections removed; (c) Signals with a baseline; (d) Signals with a baseline and with boundary
reflections removed.
 ARTICLE IN PRESS
1334 P. Kudela et al. / Mechanical Systems and Signal Processing 22 (2008) 1327–1335

Fig. 8. Numerical results: damage influence maps for a plate with two cracks (white marks). (a) Signals without a baseline; (b) Signals
without a baseline and with boundary reflections removed; (c) Signals with a baseline; (d) Signals with a baseline and with boundary
reflections removed.

influence map indicate its location (Fig. 8b), but the value of damage influence amplitude is much smaller than
that for crack no. 1. Obviously, the front wave propagating parallel to the crack generates much more
scattered waves and for this reason identification of the position of crack no. 1 is easier.
Signals used by the algorithm can be related to the signals obtained for the plate with no damage. Such
differential signals carry all essential information about the presence of damage and can be very effectively
used (Figs. 7c and 8c). The location of a crack can be estimated with sufficient precision. The difference
between the maximum of the damage influence amplitude and the centre of the crack is less then 3 mm in the
case of one crack (Fig. 7d) and less than 10 mm in the case of two cracks (Fig. 8d).
Considering a clock-like PZT element as a moving monitoring tool, the dead zone presented in Fig. 4 could
be reduced and in a few stages a large area of a structure may be inspected. Another possibility is to cover the
area of a structure by few clock-like PZT elements and to monitor the structure online.

5. Conclusions

Spectral element method enables accurate modelling of the wave propagation phenomena in anisotropic
media with failures. In composite materials wave propagates in each direction with different velocity and this
information should be included in a damage detection algorithm. As a consequence of this property it is easier
to design a monitoring system with the clock-like PZT configuration than with a regular grid of sensors. The
proposed method of damage detection enables one to produce damage influence maps. Such maps show the
location and the severity of damage. The developed damage detection algorithm is universal and can be
applied to any sensor configuration.
 ARTICLE IN PRESS
P. Kudela et al. / Mechanical Systems and Signal Processing 22 (2008) 1327–1335 1335

References

[1] T. Fukuda, T. Kosaka, Cure and health monitoring, Encyclopedia of Smart Materials, Wiley, New York, 2002, pp. 291–318.
[2] P. Wilcox, M. Lowe, P. Cawley, The effect of dispersion on long-range inspection using ultrasonic guided waves, NDT&E
International 34 (2001) 1–9.
[3] A. Patera, A spectral element method for fluid dynamics: laminar flow in a channel expansion, Journal of Computational Physics 54
(1984) 468–488.
[4] P. Kudela, M. Krawczuk, W. Ostachowicz, M. Palacz, A. Żak, Wave propagation modelling in composite plates with damage, in:
Proceedings of the 3rd European Workshop on Structural Health Monitoring, 2006.
[5] V. Giurgiutiu, J. Bao, Embedded-ultrasonics structural radar for in situ structural health monitoring of thin-wall structures, Structural
Health Monitoring 3 (2) (2004) 121–140.
[6] C. Wang, T. Rosej, F.-K. Chang, A synthetic time-reversal imaging method for structural health monitoring, Smart Materials and
Structures 13 (2004) 415–423.
[7] P. Wilcox, Omni-directional guided wave transducer arrays for the rapid inspection of large areas of plate structures, IEEE
Transactions on Ultrasonics, Ferroelectric, and Frequency Control 50 (6) (2003) 699–709.