Metals which are widely used in many types of industries are usually subjected to fatigue and surface corrosion. There is a demand to detect the surface damage caused by fatigue and corrosion at an early stage to ensure the structural integrity. In this paper, a novel nonlinear ultrasonic technique based on the measure of third-order combined harmonic generation, is proposed to detect and locate the surface damage in 6061 aluminum alloy. Third-order combined harmonic generation caused by non-collinear mixing of one longitudinal wave and one transverse wave at different frequencies, is firstly analyzed and experimentally observed. An experimental procedure of nonlinear scanning is proposed for the damage detection and location by checking the variation of frequency nonlinear response. The correlations of nonlinear frequency mixing responses and surface damage in the specimens are obtained. Results show that the nonlinear response caused by fatigue damage and surface corrosion can be identified and located by this method. In addition, this approach can exclude the nonlinearity induced by the instruments and simplify the signal processing.
Keywords: fatigue damage; non-collinear mixing; nonlinearity; surface corrosion.