Ultrasonic phased array imaging of multi-layered structures using full-matrix migration and normalized cross-correlation matching technique

Multi-layered structures play a critical role in aerospace, automotive and electrical industries, so the non-destructive evaluation and maintenance of such structures must be accurate and rapid. The application of conventional ultrasonic phased array imaging methods is limited due to computational complexity, image quality and image size. In this paper, we proposed a cost-effective, high-quality imaging method that uses full-matrix migration total focus method (FM-TFM) and produces large-area scanned image with the aid of normalized cross-correlation (NCC) template matching technique. The FM-TFM method eliminated the need for iterative refraction point calculations by using full matrix migration extrapolation, and the optimization of NCC was also investigated in the study. The verification was divided into two parts, fixed transducer experiment and manual scanned experiment, to demonstrate the advantages of FM-TFM with improved SNR (22% or greater) and one order of magnitude reduction in computational time when compared to ray tracing total focus method (RT-TFM) and NCC matching accuracy of multilayer specimen, respectively. The proposed method can help eliminate the need for costly scanning equipment and shows great potential for extension to other TFM-based approaches.