Because of the ability to protect and decorate materials, polyurethane coatings (PU) are being applied more and more extensively in the transportation, furniture, automotive, and electronic industries. However, it is difficult to effectively evaluate the bonding quality of coatings by conventional destructive methods for high-volume products in industrial applications. In this work, an ultrasonic nondestructive method based on the feedforward comb filtering effect was proposed to assess the bonding strength of the PU coatings. The coating and substrate interface can be modeled as a distributed spring system. The phase of the reflected ultrasonic wave is highly related to the interfacial stiffness. The superimposed signals can be well analyzed based on the comb filtering effect, and an index called the ratio of notch frequencies to interval frequencies (NIR) was constructed to represent the phase difference. Finite element simulations were conducted to show the index's construction method and variation with different interfacial stiffnesses. Immersed ultrasonic testing experiments with a transducer of 39.43 MHz were then conducted on PU coatings on two kinds of substrates made of aluminum and magnesium alloys. Each specimen was scanned as a grid to mimic the procedure of the well-known cross-cut test. The notch frequencies of the scanned received signals were applied to obtain the NIR index. To avoid the interference of the thickness of coatings, the decimal part of NIR was further proposed to link with the bonding strength obtained by the cross-cut test. This index changes accordingly with aluminum- and magnesium-based coatings' bonding strength. The results prove that the proposed ultrasonic method based on the feedforward comb filter effect is high potential to assess the bonding strength of coatings nondestructively.
Keywords: Bonding strength; Feedforward comb filter; Nondestructive testing; Notch frequency; Polyurethane coatings.
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