Ultrasonic Sensors and Methods

The "Ultrasonic sensors and methods" workgroup of Fraunhofer IKTS at the Dresden Klotzsche site is in charge of methodical planning and simulation-based optimization of ultrasonic-based test methods as well as their implementation in devices and equipment. The latter is done primarily based on the institute’s own PCUS^® pro-Plattform. The devices and software of the PCUS^® pro family are developed by the groups "Electronics for testing systems" and "Software for testing systems". If required, highly sensitive and reliable ultrasonic probes and sensors for special applications complete the platform. These are designed and manufactured in the institute’s own lab.

The complexity of novel materials and components implicate that simulation-based planning and optimization of probes and the continuous adaptation of test methods are gaining in importance. The complete test sequence including sensors can be simulated beforehand on the computer. The purpose is to test the set-up for physical plausibility and sensitivity and make the manufacturing process more economically efficient.

When development times are short, modeling and simulation help to avoid bad planning and enable a systematical optimization of test parameters. With this aim in mind, the »Ultrasonic sensors and processes« workgroup has for many years been developing its own high-performing computing programs and imaging analysis algorithms. These are available in a module library which can be extended in an efficient way and quickly adapted to suit new test requirements and tasks.

Where commercially available probes are not suited for specific applications, the sensor lab of IKTS is able to design and manufacture customized ultrasonic transducers. High-performance simulation tools and equipment such as a dicing saw, d33 meter (piezometer) and HF pulser-receivers up to 500 MHz are available for this purpose. 

Some examples for specialized applications are high-temperature sensors, high-frequency aluminum nitride thin-film transducers, curved piezocomposite probes as well as highly sensitive transducers based on piezoelectric monocrystals, such as lead magnesium niobate/lead titanate (PMN-PT). The available transducer types are single-element transducers, phased-array sensors, acoustic emission sensors and transmit/receive probes. They can be adapted for special component geometries and integrated in test pliers.

The "Ultrasonic sensors and methods" workgroup realizes and coordinates the full integration of methods and algorithms in client-specific hardware and software. The group is also in charge of converting test methods into equipment, down to the construction of industrial prototypes in Germany and abroad.

The group currently focuses on developing special high-resolution scanners and robot-based testing systems for free-form components with complex shapes and of various material classes.